Maintenance Task Schedule Comparison of Changes - pre ... Updates/All...Page 24: 05-05 COAL FIRED...

Maintenance Task Schedule

Comparison of Changes - pre and post November 2012

All changes

November 2012

Whilst reasonable steps have been taken to ensure that the information contained within this report is correct, you should be aware that the information contained within it may be incomplete, inaccurate or may have become out of date. Accordingly,

B&ES Publications make no warranties or representations of any kind as to the content of this report or its accuracy and, to the maximum extent permitted by law, accept no liability whatsoever for the same including, without limit, for direct, indirect or

consequential loss, business interruption, loss of profits, production, contracts, goodwill or anticipated savings. Any person making use of this report does so at his or her own risk [and it is recommended that they seek professional advice from their

own adviser whenever appropriate].

Table Of Contents

Groups Maintenance Task Schedules

Page 1: ACTUATORS

Page 10: AIR CONDITIONING

Page 12: AIR HANDLING UNITS

Page 14: BELTS

Page 16: BOILERS/HEAT GENERATORS

Page 77: BUILDING MANAGEMENT SYSTEMS

Page 85: BURNERS

Page 93: CHILLERS - WATER

Page 100: COLD ROOMS AND FOOD STORAGE

Page 103: COMMUNICATION AND P.A. SYSTEMS

Page 106: COMPRESSORS - REFRIGERATION

Page 114: CONDENSERS

Page 117: CONTROL PANELS & CONTROLLERS

Page 144: DUCTING

Page 149: DUCTWORK CLEANING

Page 151: ELECTRICS IN BUILDINGS

Page 154: EVAPORATORS

Page 157: FANS

Page 174: FILTERS

Page 180: FIRE ALARM SYSTEMS

Page 189: FIRE PROTECTION SYSTEMS

28: FLUES

Page 230: FOUNTAINS

Page 234: GRILLES AND DIFFUSERS

Page 237: HAZARDOUS AREA (ELECTRICS)

Page 243: HEAT EMITTERS

Page 260: HEAT EXCHANGERS

Page 271: HEAT REJECTION SYSTEMS

Page 282: HIGH VOLTAGE WORKS

Page 309: HOT & COLD WATER SERVICES

Page 313: HOT WATER SUPPLY

Page 335: HUMIDIFIERS INCLUDING DISINFECTION PROCEDURES

Page 347: ICE MAKING MACHINES

Page 350: INSULATION

Page 352: LIGHTING

Page 358: LIGHTING- EMERGENCY

Page 366: LIGHTNING PROTECTION

Page 369: MOTORS

Page 371: PIPEWORK SYSTEMS

Page 390: PNEUMATICS

Page 392: PORTABLE EQUIPMENT

Page 397: POWER GENERATORS

Page 406: POWER SUPPLIES

Page 417: PUMPS

Page 437: REFRIGERANT DISTRIBUTION SYSTEM

Page 441: ROOM AIR CONDITIONERS

Page 444: SANITARY AND WASTE WATER PLUMBING

Page 454: SECURITY SYSTEMS

Page 456: SENSORS AND SWITCHING DEVICES

Page 467: SEWAGE TREATMENT WORKS

Page 479: SHOWERS

Page 482: SMOKE EXTRACT

Page 2: 01-01 INTRODUCTORY PROCEDURES

Page 3: 01-02 PRE-MAINTENANCE PROCEDURES

Page 4: 01-03 THERMAL ACTUATORS

Page 5: 01-04 PNEUMATIC ACTUATORS

Page 6: 01-05 HYDRAULIC ACTUATORS

Page 7: 01-06 MOTOR DRIVEN ACTUATORS

Page 8: 01-07 POWER FAIL - MOTOR RETURN ACTUATORS

Page 9: 01-08 POWER FAIL - SPRING RETURN ACTUATOR


Page 13: 03-01 AIR HANDLING UNITS - general

Page 15: 04-01 BELT DRIVES



Page 20: 05-03 ATMOSPHERIC GAS BURNER - FREE STANDING BOILER

Page 22: 05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER

Page 24: 05-05 COAL FIRED BOILERS Bunkers and Conveyors.

Page 25: 05-06 COAL FIRED BOILERS - Coal storage handling and feed mechanisms, automatic ash removal (where fitted)

Page 26: 05-07 COAL FEED MECHANISMS - Under feed stokers

Page 27: 05-08 COAL FEED MECHANISMS - Chain grate stokers

Page 28: 05-09 ASH HANDLING SYSTEM

Page 29: 05-10 BLOWN GAS BURNER CONDENSING BOILER

Page 30: 05-11 BLOWN GAS BURNER MODULAR BOILER

Page 31: 05-12 FORCED DRAUGHT GAS CONDENSING BOILER

Page 32: 05-13 FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER

Page 33: 05-14 BOILERS MTHW UP TO 120 oC

Page 34: 05-15 MULTIPLE BOILERS - sequence controls

Page 35: 05-16 BOILER CONTROLS - Single boiler: on/off

Page 36: 05-19 STEAM BOILERS Pre-maintenance check.

Page 37: 05-20 STEAM BOILERS Maintenance schedule.

Page 40: 05-21 ELECTRIC BOILERS

Page 41: 05-22 ELECTRODE BOILERS

Page 42: 05-23 BOILERS LTHW UP TO 95ºC

Page 43: 05-24 BOILERS - FIRE AND SAFETY CIRCUITS

Page 44: 05-25 WASTE AND WOOD BURNING APPLIANCES (including boilers) - Fire And Boiler Safety Circuits

Page 45: 05-26 WASTE AND WOOD BURNING APPLIANCES (including boilers) - Combustion Chamber

Page 46: 05-27 WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if fitted)

Page 47: 05-28 Atmospheric Gas Burner Boiler - Small and/or wall hung for domestic/light commercial installation

Page 49: 05-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER

Page 51: 05-30 ATMOSPHERIC GAS BURNER/CONDENSING COMBINATION BOILER

Page 53: 05-31 AIR TO WATER HEAT PUMP

Page 54: 05-32 WATER TO WATER HEAT PUMP

Page 55: 05-33 BRINE TO WATER HEAT PUMP

Page 56: 05-34 PACKAGED STEAM GENERATORS

Page 59: 05-35 PAKAGED STEAM GENERATORS - ELECTRIC

Page 60: 05-36 STEAM BOILER REPORT - PERIODIC EXAMINATION

Page 61: 05-37 BOILER SUPERHEATER

Page 62: 05-38 BIOMASS BOILER

Page 64: 05-39 GAS BOOSTER SETS

Page 65: 05-40 GAS GOVERNOR OR GAS REGULATOR

Page 66: 05-41 GAS INCINERATOR

Page 68: 05-42 WASTE INCINERATOR

Page 72: 05-43 WET SCRUBBER SYSTEM

Contents Page 1 of 7

SOLAR PANELS

Page 488: SPLIT SYSTEMS INCLUDING HEAT PUMPS

Page 497: STARTERS

Page 507: STORAGE TANKS

Page 524: SWIMMING POOLS

Page 535: SWITCHES

Page 538: TERMINAL UNITS

Page 553: VACUUM SYSTEMS

Page 556: VALVES

Page 566: VALVES -AUTOMATIC CONTROL

Page 573: VEHICLE ACCESS

Page 576: VENTILATION ANCILLARIES

Page 585: WATER TREATMENT

Page 608: WHIRLPOOLS-HYDROTHERAPY

Page 74: 05-44 FABRIC FILTER SYSTEM

Page 76: 05-45 SANITARY INCINERATOR


Page 80: 06-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station

Page 82: 06-04 BUILDING MANAGEMENT SYSTEMS - COMMUNICATIONS

Page 83: 06-05 BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS

Page 84: 06-06 BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS

Page 86: 07-01 ATMOSPHERIC GAS BURNERS

Page 87: 07-02 BLOWN GAS BURNER

Page 88: 07-03 FORCED DRAUGHT GAS BURNER

Page 89: 07-04 FUEL OIL DISTRIBUTION & PIPEWORK USING MEDIUM (220/960 Sec) OIL

Page 90: 07-05 FORCED DRAUGHT [PRESSURE JET] OIL BURNER

Page 91: 07-06 LIGHT OIL VAPORISING POT BURNER

Page 92: 07-07 GAS/OIL BURNERS - Dual fuel


Page 95: 09-02 PACKAGED CHILLER UNITS

Page 98: 09-03 LITHIUM BROMIDE/WATER ABSORPTION CHILLERS

Page 99: 09-04 GAS FIRED ABSORPTION CHILLER UP TO 18 KW COOLING CAPACITY

Page 101: 10-01 COLD ROOMS

Page 102: 10-02 REFRIGERATED DISPLAY CABINETS

Page 104: 11-01 COMMUNICATIONS - PUBLIC ADDRESS SYSTEMS

Page 107: 12-01 COMPRESSORS REFRIGERATION - Reciprocal - (includes hermetic, semi-hermetic and open)

Page 109: 12-02 COMPRESSOR - SCREW

Page 110: 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL

Page 112: 12-04 COMPRESSOR - SCROLL

Page 115: 13-01 CONDENSERS - water cooled

Page 116: 13-02 CONDENSER - air cooled

Page 118: 14-01 CONTROL PANELS AND CONTROLLERS INTRODUCTORY PROCEDURES

Page 119: 14-02 CONTROL PANELS - electrical services (excluding electrical controllers and pneumatic relays)

Page 120: 14-03 CONTROL PANELS - lamps, meters, alarms etc.

Page 121: 14-04 OPTIMISER

Page 122: 14-05 HEATING COMPENSATOR

Page 123: 14-06 SINGLE INPUT CONTROLLER


Page 125: 14-07 UNIT CONTROLLERS AND SENSOR CONTROLLERS


Page 127: 14-08 CONTROLLER TIMERS


Page 129: 14-09 STEP CONTROLLERS


Page 131: 14-10 TIMESWITCHES


Page 133: 14-11 MULTI-INPUT CONTROLLERS


Page 135: 14-12 INDICATORS AND DISPLAYS

Page 136: 14-13 ALARM MODULES

Page 137: 14-14 LEVEL CONTROLLERS


Page 139: 14-15 SPEED CONTROLLERS


Page 141: 14-16 TRANSDUCERS - pneumatic to electronic and electronic to pneumatic

Page 142: 14-17 DIRECT CURRENT [DC] DRIVES

Page 143: 14-18 EMERGENCY STOP BUTTONS

Page 145: 16-01 DUCTING AND AIR DISTRIBUTION INTRODUCTORY PROCEDURES

Page 146: 16-02 DUCTWORK SYSTEM - GENERAL

Page 147: 16-03 DUCTING - VOLUME CONTROL DAMPERS AND FIRE/ SMOKE DAMPERS

Page 148: 16-04 DUCTING - Attenuators

Page 2 of 7

17-01 DUCTWORK CLEANING HYGIENE, INSPECTIONS & MONITORING


Page 155: 19-01 REFRIGERATION EVAPORATORS


Page 159: 20-02 FANS - VENTILATING - general

Page 161: 20-03 FANS -CENTRIFUGAL

Page 163: 20-04 FANS- AXIAL

Page 165: 20-05 FANS - PROPELLER

Page 167: 20-06 FANS-MIXED FLOW

Page 169: 20-07 FANS-BIFURCATED

Page 171: 20-08 FANS-EXTRACT - including fire/smoke extracts units

Page 172: 22-02 FIRE ALARMS - Associated Equipment


Page 176: 21-02 AIR FILTERS

Page 179: 21-03 ELECTROSTATIC FILTERS

Page 181: 22-01 FIRE ALARM SYSTEM


Page 191: 23-02 HOSE REELS PRESSURE BOOSTING SETS

Page 192: 23-03 HOSE REELS - Static or Swinging

Page 194: 23-04 RISING FIRE MAINS and HYDRANTS

Page 195: 23-05 Gas Extinguishing systems

Page 197: 23-06 CARBON DIOXIDE TOTAL FLOODING FIRE EXTINGUISHING SYSTEM

Page 199: 23-07 EXPANSION FOAM SYSTEMS

Page 202: 23-08 FIRE EXTINGUISHERS - GAS SUPPRESSION (Halon)

Page 203: 23-09 FIRE EXTINGUISHERS - CARBON DIOXIDE

Page 205: 23-10 FIRE EXTINGUISHERS - FOAM (Stored Pressure)

Page 208: 23-11 FIRE EXTINGUISHERS - POWDER (GAS CARTRIDGE)

Page 213: 23-12 FIRE EXTINGUISHERS - WATER - GAS CARTRIDGE

Page 217: 23-13 FIRE EXTINGUISHERS - WATER STORED PRESSURE

Page 220: 23-14 SPRINKLER SYSTEMS

Page 225: 23-15 GAS DETECTION

Page 226: 23-16 KITCHEN HOOD FIRE SUPPRESSION

Page 229: 24-01 FLUES (all combustible fuels)

Page 231: 25-01 FOUNTAINS OUTDOOR - ORNAMENTAL

Page 232: 25-02 FOUNTAINS INDOOR - ORNAMENTAL

Page 235: 26-01 GRILLES AND DIFFUSERS

Page 236: 26-02 LOUVRES, BIRD AND INSECT SCREENS


Page 239: 27-02 Hazardous areas - FLAME PROOF EQUIPMENT

Page 240: 27-03 Hazardous areas - LIGHTING

Page 241: 27-04 Hazardous areas - EARTHING

Page 244: 28-01 HEAT EMITTERS

Page 248: 28-02 GAS FIRED CERAMIC PLAQUE INFRA RED HEATERS

Page 250: 28-03 GAS RADIANT TUBE HEATERS

Page 252: 28-04 GAS FIRED NATURAL AND FAN ASSISTED HEATERS - Conventional and Balanced Flue.

Page 253: 28-05 GAS FIRE

Page 255: 28-06 GAS FIRED UNIT HEATERS

Page 257: 28-07 GAS FIRED RADIANT HEATERS

Page 261: 29-01 HEAT EXCHANGERS - COILS

Page 263: 29-02 ELECTRIC/AIR HEATER

Page 264: 29-03 PLATE RECUPERATOR

Page 265: 29-04 THERMAL WHEELS - ROTARY HEAT REGENERATORS

Page 266: 29-05 RUN AROUND HEAT RECOVERY COILS

Page 267: 29-06 PLATE HEAT EXCHANGERS

Page 268: 29-07 WATER TO WATER PLATE HEAT EXCHANGERS

Page 269: 29-08 HEATING CALORIFIERS - MTHW, HTHW or STEAM


Page 3 of 7

30-02 COOLING TOWERS - Precautions against Legionnaires disease (legionella pneumophila)

Page 278: 30-03 DRY COOLERS

Page 280: 30-04 ADIABATIC COOLERS


Page 284: 70-02 HV PACKAGED SUBSTATIONS

Page 286: 70-03 OIL SWITCHGEAR INCLUDING OIL CIRCUIT BREAKERS AND OIL SWITCHES

Page 290: 70-04 NON-OIL SWITCHGEAR

Page 296: 70-05 VACUUM INDOOR SWITCHGEAR

Page 299: 70-06 FLUID FILLED TRANSFORMER

Page 302: 70-07 CAST RESIN TRANSFORMER

Page 305: 70-08 RING MAIN UNIT

Page 307: 70-09 HV SWITCHPANEL



Page 316: 32-02 HOT WATER SERVICES general

Page 317: 32-03 CALORIFIER TYPES


Page 319: 32-05 CALORIFIERS HEATED BY LTHW

Page 320: 32-06 HOT WATER CALORIFIERS HEATED BY MTHW, HTHW or STEAM

Page 322: 32-07 HOT WATER SUPPLY CALORIFIERS

Page 324: 32-08 CALORIFIER AND HEAT EXCHANGE CONTROLS

Page 325: 32-09 HOT WATER CYLINDERS

Page 327: 32-10 UNVENTED HOT WATER SYSTEMS

Page 328: 32-11 THERMAL STORAGE CYLINDER (individual dwellings for DHWS)

Page 330: 32-12 EXPANSION VESSELS

Page 331: 32-13 DIRECT FIRED WATER HEATERS

Page 332: 32-14 INSTANTANEOUS ELECTRIC WATER HEATERS (non drinks type)

Page 333: 32-15 PACKAGED ELECTRIC WATER HEATERS-cistern type (non drinks)

Page 334: 32-16 VENTED HOT WATER SYSTEMS

Page 336: 33-01 HUMIDIFIER - Cold water evaporator, drum type

Page 337: 33-02 HUMIDIFIER - Direct steam injection type.

Page 340: 33-03 ELECTRODE BOILER HUMIDIFIER

Page 341: 33-04 HUMIDIFIERS- Compressed air type

Page 343: 33-05 HUMIDIFIERS- Ultra sonic

Page 344: 33-06 HUMIDIFIERS- Resistance heater type

Page 345: 33-07 HUMIDIFIER - Disinfection procedures

Page 346: 33-08 SPRAY HUMIDIFIERS

Page 348: 34-01 ICE MAKING MACHINES

Page 351: 35-01 THERMAL INSULATION


Page 354: 36-02 LIGHTING-SWITCHES-INTERNAL AND EXTERNAL

Page 355: 36-03 LIGHTING FITTINGS including LUMINAIRES general

Page 356: 36-04 EXTERNAL LIGHTING including ILLUMINATED SIGNS

Page 359: 37-01 EMERGENCY LIGHTING self contained

Page 361: 37-02 EMERGENCY LIGHTING externally powered

Page 363: 40-04 CHILLED WATER-CONDENSER WATER PIPE SYSTEMS

Page 364: 40-05 CONDENSER - CHILLED WATER CIRCULATING PUMPS

Page 365: 40-06 PRESSURISATION UNITS - CHILLED WATER

Page 367: 38-01 LIGHTNING CONDUCTOR AND EARTH

Page 370: 39-01 MOTORS- DRIVE ELEMENTS

Page 372: 40-01 PIPEWORK SYSTEMS - General

Page 373: 40-03 PIPEWORK SYSTEMS-TRACE HEATING

Page 374: 40-07 PNEUMATIC EQUIPMENT – COMPRESSED AIR SYSTEMS

Page 375: 40-08 AIR COMPRESSORS AND RECEIVERS

Page 379: 40-09 AIR COMPRESSORS Compressed air dryers

Page 380: 40-10 PIPEWORK FOR LOW PRESSURE NATURAL GAS, LIQUEFIED PETROLEUM GAS (LPG) OR OIL

Page 382: 40-11 STEAM SERVICES

Page 4 of 7

40-12 FLASH STEAM VESSEL

Page 386: 40-13 EMERGENCY SOLENOID FUEL VALVES

Page 387: 40-15 PRESSURE REDUCING VALVES

Page 388: 40-16 WATER BUFFER/SURGE TANKS

Page 389: 40-17 WATER MAINS - above ground

Page 391: 41-01 PNEUMATIC RELAYS

Page 393: 42-01 PORTABLE APPLIANCE TESTING (PAT)


Page 399: 43-02 POWER GENERATION--STAND-BY GENERATOR

Page 403: 43-03 BATTERIES - LEAD ACID - unsealed

Page 404: 43-04 BATTERY CHARGING EQUIPMENT

Page 405: 43-05 UNINTERRUPTIBLE POWER SUPPLIES


Page 408: 44-02 MAIN SWITCH PANEL AT SUPPLY INTAKE

Page 410: 44-05 POWER DISTRIBUTION UNIT (PDU)

Page 412: 44-06 EARTHING

Page 413: 44-07 DISTRIBUTION BOARDS

Page 414: 44-08 ELECTRICAL INSTALLATION - GENERALLY

Page 416: 44-10 ISOLATORS/STARTERS/FUSESWITCHES

Page 418: 45-01 PUMPS - General

Page 420: 45-02 CIRCULATING PUMPS-general

Page 421: 45-03 CENTRIFUGAL PUMPS

Page 423: 45-04 PRESSURISATION PUMPS

Page 425: 45-05 ROTARY HAND PUMPS

Page 426: 45-06 SECONDARY HOT WATER CIRCULATING PUMPS

Page 427: 45-07 SEWAGE OR DRAINAGE PUMPS SUBMERSIBLE

Page 429: 45-08 SEWAGE and DRAINAGE PUMPS: DRYWELL

Page 431: 45-09 SEWAGE PUMPS: COMPRESSED AIR

Page 432: 45-10 SUMP PUMPS: EXTENDED SHAFT

Page 434: 45-12 WATER PUMPING PRESSURE BOOSTING SETS

Page 436: 45-13 OGDEN STEAM PUMP

Page 438: 46-01 REFRIGERANT DISTRIBUTION SYSTEM

Page 442: 47-01 ROOM AIR CONDITIONERS


Page 446: 48-02 MACERATORS

Page 447: 48-03 INTERCEPTORS - Petrol and Oil

Page 448: 48-04 INTERCEPTORS - blowdown and sumps

Page 450: 48-05 SANITARY, WASTE WATER PLUMBING and DRAINS

Page 452: 48-06 AIR ADMITTANCE VALVES

Page 453: 48-08 SANITARY AND WASTE WATER PLUMBING - WATER SAVING DEVICES and METERS

Page 455: 49-01 SECURITY SYSTEMS-INTRUDER ALARMS


Page 458: 50-02 PRESSURE MEASUREMENT SENSORS - static and differential

Page 459: 50-03 TEMPERATURE MEASUREMENT SENSORS

Page 460: 50-04 RELATIVE HUMIDITY SENSORS

Page 461: 50-05 ABSOLUTE HUMIDITY SENSORS

Page 462: 50-07 CARBON DIOXIDE SENSORS

Page 463: 50-08 VELOCITY SENSORS

Page 464: 50-09 OCCUPANCY and LIGHT SENSORS

Page 465: 50-10 SMOKE DETECTORS

Page 466: 50-11 GAS DETECTOR SENSORS


Page 469: 71-02 SEWAGE TREATMENT WORKS - package systems

Page 471: 71-03 SEWAGE TREATMENT WORKS - EXTENDED AERATION AND OXIDATION DITCH SYSTEMS

Page 475: 71-04 DRAINAGE FIELDS

Page 476: 71-05 SETTLEMENT TANKS

Page 477: 71-06 SEPERATOR SYSTEMS

Page 5 of 7

51-01 SHOWERS

Page 481: 51-02 SHOWERS BOOSTER PUMPS

Page 483: 52-02 SMOKE RELIEF - Natural smoke and heat exhaust ventilators

Page 484: 52-03 SMOKE RELIEF - Powered smoke and heat exhaust ventilators

Page 485: 52-04 SMOKE CURTAINS

Page 487: 53-01 SOLAR HOT WATER PANELS and similar COLLECTING DEVICES


Page 490: 54-02 DX SPLIT SYSTEMS - with gas, electric or hot water heaters

Page 494: 54-03 SPLIT SYSTEMS/ HEATPUMPS – air-cooled with direct expansion evaporator (DX)

Page 498: 55-01 DRIVE ELEMENTS - STARTERS

Page 499: 55-02 STARTERS - Star Delta

Page 500: 55-03 STARTERS -Two speed - Dual wound

Page 501: 55-04 STARTERS - Two speed - Pole change

Page 502: 55-05 STARTERS - Reversing

Page 503: 55-06 STARTERS - Auto-transformer

Page 504: 55-07 STARTERS - Quick transition, electric heater

Page 505: 55-08 STARTERS electrolyte type

Page 506: 55-09 STARTERS-AIR BREAK AND CONTACTORS


Page 511: 56-02 COLD WATER STORAGE TANKS and CISTERNS

Page 514: 56-03 ICE STORAGE SYSTEMS

Page 516: 56-05 STORAGE TANKS - OIL

Page 519: 56-06 UNDERGROUND OIL STORAGE TANKS

Page 522: 56-07 STORAGE SILO - wood chip / pellets

Page 523: 56-08 STORAGE SILO - COAL


Page 526: 57-02 SWIMMING POOLS

Page 530: 57-03 SWIMMING POOLS - FILTERS

Page 532: 57-04 SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.

Page 536: 58-01 ON/OFF SWITCHING DEVICES

Page 537: 58-02 CONTROL RELAYS

Page 539: 59-01 TERMINAL UNITS VAV - self powered


Page 541: 59-02 TERMINAL UNITS VAV - fan powered


Page 543: 59-03 TERMINAL UNITS VAV - pneumatic powered


Page 545: 59-04 TERMINAL UNITS - Constant volume including mixing


Page 547: 59-05 TERMINAL UNITS - INDUCTION UNITS


Page 549: 59-06 TERMINAL UNITS - FAN COIL

Page 550: 59-07 TERMINAL UNITS VRV SYSTEMS


Page 554: 60-01 VACUUM SYSTEMS - general

Page 555: 60-02 VACUUM TUBES - cash handling

Page 557: 61-01 VALVES

Page 560: 61-02 TAP AND OUTLET FITTINGS

Page 561: 61-03 SERVICE VALVES

Page 562: 61-04 COMBINATION TAP ASSEMBLIES, MIXING VALVES/TAPS

Page 565: 61-05 SHOWER VALVES

Page 567: 62-01 PRE - MAINTENANCE PROCEDURES

Page 568: 62-02 ROTARY VALVES - Shoe or Slipper

Page 569: 62-03 BUTTERFLY AND BALL VALVES

Page 570: 62-04 SELF ACTING and THERMAL VALVES

Page 571: 62-05 SOLENOID VALVES

Page 572: 62-07 SEAT VALVES

Page 6 of 7

63-01 UNDERFLOOR HEATING including VEHICLE ACCESS RAMPS

Page 575: 63-02 AUTOMATIC VEHICLE BARRIER


Page 578: 64-02 MOTOR DRIVEN EXHAUST HOSE REEL

Page 579: 64-03 SPRING RECOIL HOSE REEL

Page 580: 64-04 MOBILE DUST SEPARATOR FOR SPOT EXTRACTION

Page 581: 64-05 MOBILE ELECTRONICALLY CONTROLLED CYCLONE SEPARATOR

Page 582: 64-06 VEHICLE EXHAUST RAIL SYSTEM

Page 583: 64-07 WOOD DUST EXTRACTION


Page 589: 65-02 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - commercial

Page 591: 65-03 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic (capacity usually below 50 litres)

Page 593: 65-04 SPECIAL WATER TREATMENT SYSTEMS

Page 594: 65-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant

Page 595: 65-06 FILTRATION and CONDITIONING - POINT OF USE

Page 596: 65-07 REVERSE OSMOSIS

Page 597: 65-08 ULTRA VIOLET DISINFECTION UNIT

Page 598: 65-09 OZONATION PLANT

Page 600: 65-10 CHEMICAL DOSING

Page 602: 65-11 ADIABATIC COOLING - Introductory Information and Procedures

Page 603: 65-12 ADIABATIC COOLING SYSTEMS

Page 606: 65-13 CHLORINE DIOXIDE DOSING FOR DOMESTIC LOWLEVEL INJECTION

Page 607: 65-14 CHLORINE DIOXIDE LOW DOSING DOMESTIC WATER SYSTEMS

Page 609: 66-01 WHIRLPOOL/SPA BATHS

Page 611: 66-02 HYDROTHERAPY POOLS

Page 614: 66-03 STEAM ROOMS and HUMIDIFIERS

Page 7 of 7

ACTUATORS

Page 1 of 614

Previous

Version

Updated

Version

Reason For

Change

INTRODUCTORY PROCEDURES01-01 01-01 INTRODUCTORY PROCEDURES

The following procedures apply to all types of actuator and require that before any

maintenance is undertaken all safety precautions must be strictly adhered to. Care must be taken

to ensure that any maintenance does not unduly interfere with the system's environmental conditions.

When working on equipment it should be noted that any auxiliaries fitted may have supplies fed from

a separate circuit to that of the actuator. Therefore should the actuator supply be disconnected it

should not be taken for granted that the auxiliary supply has also been disconnected.

To check that the actuator is performing its correct task, it is immaterial as to whether it is mounted on

a damper, louvre, valve or any other piece of equipment. Its purpose is to control to a position

between two limits, by either opening, closing or moving appropriate pieces of equipment.

Other Actuator Types

The function of an actuator can be split into two main categories: ON/OFF or MODULATING. Falling

within these two categories are the seven types listed in this section.

Although the majority of actuator types are covered in the following pages, new developments may

mean that the engineer is not fully aware of the operating characteristics of the device under scrutiny.

If any doubt arises it would be preferred if the manufacturer were questioned prior to any checks or

adjustments being carried out.

An example of the above is the VAV actuator sensor controller. This is a type of actuator that has

the controller built into the actuator housing. The sensor is connected via a length of cable and will

commonly be sensing air velocity or pressure. The controller will have been set to the required VAV

box demand and these settings should not be altered without prior consultation with the client,

the VAV box manufacturer and the actuator manufacturer. In this example, cross-referencing

should be made between the Actuators, Controllers and Sensors sections.

The following procedures apply to all types of actuator and require that before any maintenance is

undertaken all safety precautions must be strictly adhered to. Care must be taken to ensure that any

maintenance does not unduly interfere with the system`s environmental conditions.

When working on equipment it should be noted that any auxiliaries fitted may have supplies fed from

a separate circuit to that of the actuator. Therefore should the actuator supply be disconnected it

should not be taken for granted that the auxiliary supply has also been disconnected.

To check that the actuator is performing its correct task, it is immaterial as to whether it is mounted on

a damper, louver, valve or any other piece of equipment. Its purpose is to control to a position

between two limits, by either opening, closing or moving appropriate pieces of equipment.

Other Actuator Types

The function of an actuator can be split into two main categories: ON/OFF or MODULATING. Falling

within these two categories are the seven types listed in this section.

Although the majority of actuator types are covered in the following pages, new developments may

mean that the engineer is not fully aware of the operating characteristics of the device under scrutiny.

If any doubt arises it would be preferred if the manufacturer were questioned prior to any checks or

adjustments being carried out.

An example of the above is the VAV actuator sensor controller. This is a type of actuator that has the

controller built into the actuator housing. The sensor is connected via a length of cable and will

commonly be sensing air velocity or pressure. The controller will have been set to the required VAV

box demand and these settings should not be altered without prior consultation with the client, the

VAV box manufacturer and the actuator manufacturer. In this example, cross-referencing should be

made between the Actuators, Controllers and Sensors sections.

Other

Page 2 of 614

Previous

Version

Updated

Version

Reason For

Change

PRE-MAINTENANCE PROCEDURES01-02 01-02 PRE-MAINTENANCE PROCEDURES

Should any discrepancies occur with the following checks the client should be informed as soon as

possible to avoid the possible uneconomical running of his plant.

The frequency of checks should be used as a minimum in the event that the actuator is

performing a safety function (i.e. on a fire and smoke damper). Lives and property could

depend upon this actuator working properly.

1. Cables. Check for signs of heat, damage, chafing or water ingress.

2. Mounting. Check mounting is in accordance with the manufacturer's recommendation.

3. Anchor points. Check security.

4. Mechanical protection. Check for soundness.

5. Earth bonding. Check connection.

Actuator torque. Check torque with a torque wrench. This check is of particular importance on spring

return type actuators because the spring will have a maximum life span. Elasticity of the spring and

hence the torque will reduce with time, if the torque is insufficient to complete the action, this could be

a hazard to life and property.

7. Working conditions. Check actuator is operating within its design ambient conditions.

Should any discrepancies occur with the following checks the client should be informed as soon as

possible to avoid the possible uneconomical running of his plant.

The frequency of checks should be used as a minimum in the event that the actuator is performing a

safety function (i.e. on a fire and smoke damper). Lives and property could depend upon this actuator

working properly.

1. Cables. Check for signs of heat, damage, chafing or water ingress.

2. Mounting. Check mounting is in accordance with the manufacturer`s recommendation.

3. Anchor points. Check security.

4. Mechanical protection. Check for soundness.

5. Earth bonding. Check connection.

Actuator torque. Check torque with a torque wrench. This check is of particular importance on spring

return type actuators because the spring will have a maximum life span. Elasticity of the spring and

hence the torque will reduce with time, if the torque is insufficient to complete the action, this could be

a hazard to life and property.

7. Working conditions. Check actuator is operating within its design ambient conditions.

Other

Page 3 of 614

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THERMAL ACTUATORS01-03 01-03 THERMAL ACTUATORS

Title NotesActionFQTitle FQ Action Notes

1. Electricity

supply.

Check supply voltage and that

polarities are correct.

If supply voltages are not found,

check to see if supply is via a

controller. Refer to manufacturer's

data sheet.

12M 1. Electricity

supply.

Where applicable, Check supply

voltage and that polarities are

correct.



controller. Refer to manufacturer`s

data sheet.

12MTechnical

2. Control signal. Check for presence and that

polarity is correct.

Refer to manufacturer's data sheet.

The previous note can also apply to

the control signal.

12M 2. Control signal. Where applicable, Check for

presence and that polarity is

correct.

Refer to manufacturer`s data sheet.


the control signal.

12MTechnical

6. Reaction to

safety signal i.e.

fire/smoke.

Check that the actuator assumes

correct position (if applicable).

See relevant control/sensor section

for this operation.

6M 6. Reaction to

safety signal i.e.

fire/smoke.




for this operation.

3MOther

9. Leakage. Check for signs of leakage of

hydraulic fluid around actuator

seals. Change seals if necessary.

See manufacturer's data sheet.12M 9. Leakage. Check for signs of leakage of fluid

around actuator seals. Change

seals if necessary.

See manufacturer`s data sheet.12MTechnical

Page 4 of 614

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PNEUMATIC ACTUATORS01-04 01-04 PNEUMATIC ACTUATORS

Pneumatic actuators do not have an electrical supply but function by air pressure alone. Therefore

should there be any loss in pressure, the performance of the actuator (and thus the whole system) will

be impaired making it inefficient.

Pneumatic actuators do not have an electrical supply but function by air pressure alone. Therefore

should there be any loss in pressure, the performance of the actuator (and thus the whole system) will

be impaired making it inefficient.

Electro/pneumatic controllers will have an electrical supply to them and therefore all necessary

precautions will need to be taken to isolate supplies.

Technical


3. Air quality. Check that any filters are clear of

water and oil (filter may not be local

to the actuator).

If water and/or oil is present, check

with manufacturer of the system

regarding required action.

12M 3. Air quality. Check that any filters are clear of

water and oil (filter may not be local

to the actuator).

If water and/or oil is present, trace

pipe work back to identify the source

of the water or oil and rectify the

problem

12MTechnical

4. Manual

operation (if fitted).

Check to ensure actuator achieves

stroke limits. Check for minimum/

maximum setting.

Ensure manual override is set to

correct position.

12M 4. Manual


Check to ensure actuator achieves

stroke limits. Check for minimum/

maximum setting.

Ensure manual override is reset to

correct automatic position.

12MTechnical

7. Actuator

function.

Check calibration - controller output

to actuator position. Note: more

than one actuator may be fed from

the control supply.

Note control pressure operation

range is correct (could be

sequenced control)

6M 7. Actuator

function.

Check calibration - controller output

to actuator position. More than one

actuator may be fed from the

control supply.

Note control pressure operation

range is correct (could be

sequenced control)

6MOther

9. Reaction to

safety signal i.e.

fire/smoke.




for this operation.

3MAdded

Page 5 of 614

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HYDRAULIC ACTUATORS01-05 01-05 HYDRAULIC ACTUATORS

(Should not be confused with pneumatic actuators) Ensure the correct grade and type of hydraulic oil is used for any topping up purposes.Technical


1. Electricity

supply.

Check supply voltage and that

polarities are correct.



controller. Refer to manufacturer's

data sheet.

12M 1. Electricity

supply.

Where applicable, check supply

voltage and that polarities are

correct.



controller. Refer to manufacturer`s

data sheet.

12MTechnical

2. Control signal. Check for presence and that

polarity is correct.

Refer to manufacturer's data sheet.


the control signal.

12M 2. Control signal. Where applicable, check for

presence and that polarity is

correct.

Refer to manufacturer`s data sheet.


the control signal.

12MTechnical

8. Leakage. Check for signs of leakage of



See manufacturer's data sheet.12M 8. Leakage. Check for signs of leakage of



On completion of the works, bleed

through the system to ensure there

is no air trapped in the pipework

See manufacturer`s data sheet.12MTechnical

Page 6 of 614

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MOTOR DRIVEN ACTUATORS01-06 01-06 MOTOR DRIVEN ACTUATORS


6. Reaction to

safety signal i.e.

fire/smoke.



The signal could be in any form from

a fusible link in the supply or gear

box to an independent signal from a

control. If the actuator is integrated

into the fire alarm circuit, checks

may have to be made whilst a fire

drill is in operation. See

manufacturer's data sheet on this

actuator and relevant control and/or

sensor section.

6M 6. Reaction to

safety signal i.e.

fire/smoke.



The signal could be in any form

from a fusible link in the supply or

gear box to an independent signal

from a control. If the actuator is

integrated into the fire alarm circuit,

checks may have to be made whilst

a fire drill is in operation. See

manufacturer`s data sheet on this

actuator and relevant control and/or

sensor section.

3MOther

Page 7 of 614

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POWER FAIL - MOTOR RETURN ACTUATORS01-07 01-07 POWER FAIL - MOTOR RETURN ACTUATORS

Power fail - Motor return actuators are commonly enabled to return to the desired position by means

of an electricity supply independent from the rest of the building. Care should be taken to monitor

the amount of operations left in the batteries and they should be replaced according to the

manufacturer's instructions. The disposal of batteries calls for special arrangements, which should

conform to all environmental and Health and Safety requirements.

Note:- If the following actuators perform a safety function e.g. fitted to a fire/smoke damper, the

frequency of checks should be taken as the maximum time between checks and reference should be

made to the particular manufacturer's recommended frequencies. It should be remembered that

people's lives and property could depend on the actuators functioning correctly.

Power fail - Motor return actuators are commonly enabled to return to the desired position by means

of an electricity supply independent from the rest of the building. Care should be taken to monitor the

amount of operations left in the batteries and they should be replaced according to the manufacturer`s

instructions. The disposal of batteries calls for special arrangements, which should conform to all

environmental and Health and Safety requirements.

If the following actuators perform a safety function e.g. fitted to a fire/smoke damper, the frequency of

checks should be taken as the maximum time between checks and reference should be made to the

particular manufacturer`s recommended frequencies. It should be remembered that people`s lives

and property could depend on the actuators functioning correctly.

Other


6. Reaction to

safety signal, e.g.

fire/smoke.



6M 6. Reaction to

safety signal, e.g.

fire/smoke.



3MLegislative

Page 8 of 614

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POWER FAIL - SPRING RETURN ACTUATOR01-08 01-08 POWER FAIL - SPRING RETURN ACTUATOR


4. Manual


Check to prove actuator will

mechanically open/close valve or

damper to its working limits.

The actuator may be fitted with the

facility to manually wind up the

spring, if so the spring must be

wound up with the recommended

tool. See manufacturer's data sheet.

If the tool is capable of being

removed, do so at the end of the

test and ensure that the actuator is

left in the original position. Ensure

that the actuator is returned to the

'auto' position (if fitted) after the

check is completed.

12M 4. Manual


Check to prove actuator will

mechanically open/close valve or

damper to its working limits.

The actuator may be fitted with the

facility to manually wind up the

spring, if so the spring must be

wound up with the recommended

tool. See manufacturer`s data

sheet. If the tool is capable of being

removed, do so at the end of the

test and ensure that the actuator is

left in the original position. Ensure

that the actuator is returned to the

`auto` position (if fitted) after the

check is completed. Care must be

taken in winding up the mechanism

to ensure then spring is not over

tensioned.

12MTechnical

7. Reaction to

safety signal, e.g.

fire smoke.



This signal could be in any form,


gearbox to an independent signal




a fire drill is in operation.

6M 7. Reaction to

safety signal, e.g.

fire smoke.



This signal could be in any form,


gearbox to an independent signal




a fire drill is in operation.

3MOther

Page 9 of 614

AIR CONDITIONING

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Air conditioning systems range from the single wall/window mounted unit to large installations having

compressor drives of several hundred kW. The maintenance requirements of the various systems will

differ widely in complexity and skill requirements and this is reflected in the breakdown of this

document. Two environmental problems associated with air conditioning plant , namely the potential

depletion of the ozone layer through the release of chlorofluorocarbons (CFCs) and Legionnellosis

from untreated water systems, demonstrates the need for maintaining plant at the highest standard as

is outlined in this Standard Maintenance Specification.

Care is also required in the disposal of CFCs. Any practice which releases CFCs into the

atmosphere must not be used. Specialist contractors will have refrigeration engineers who have

been trained and certified in the handling of CFCs and will have access to and use proper recovery

equipment. These contractors must belong to an Approved Certfied Scheme provider, in accordance

with the "F" Gas and Building Regulations. It is in the building owners’ interest to ensure that plant is

properly maintained to ensure environmental conditions in the building are acceptable to the staff and

that energy is not wasted.

In a subject as complicated as the maintenance of air conditioning plant an approach has been

selected which breaks the systems down into their component parts such as compressors,

condensers, and evaporators or chillers, refrigerant distribution systems with their associated controls.

Central and room air conditioning plant are examined in the appropriate detail as Air Handling Units ,

Humidifiers, Heat Rejection Unitary Air Conditioners. It must be emphasised that although this

modular approach has been adopted it is the system as a whole, which must be maintained on a

regular basis using this Standard Maintenance Specification.

Air conditioning systems range from the single wall/window mounted unit to large installations having

compressor drives of several hundred kW. The maintenance requirements of the various systems will

differ widely in complexity and skill requirements and this is reflected in the breakdown of this

document. Two environmental problems associated with air conditioning plant , namely the potential

depletion of the ozone layer through the release of refrigerants and Legionnellosis from untreated

water systems, demonstrates the need for maintaining plant at the highest standard as is outlined in

this Standard Maintenance Specification.

Care is also required in the disposal of refrigerants. Any practice which releases refrigerants into the

atmosphere must not be used. Specialist contractors will have refrigeration engineers who have been

trained and certified in the handling of refrigerants and will have access to and use proper recovery

equipment. These contractors must belong to an Approved Certified Scheme provider , in accordance

with the "F" Gas and Building Regulations. It is in the building owners’ interest to ensure that plant is

properly maintained to ensure environmental conditions in the building are acceptable to the staff and

that energy is not wasted.

In a subject as complicated as the maintenance of air conditioning plant an approach has been

selected which breaks the systems down into their component parts such as compressors,

condensers, and evaporators or chillers, refrigerant distribution systems with their associated controls.

Central and room air conditioning plant are examined in the appropriate detail as Air Handling Units ,

Humidifiers, Heat Rejection Unitary Air Conditioners. It must be emphasised that although this

modular approach has been adopted it is the system as a whole, which must be maintained on a

regular basis using this Standard Maintenance Specification.

Other

Page 11 of 614

AIR HANDLING UNITS

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AIR HANDLING UNITS - general03-01 03-01 AIR HANDLING UNITS - general


1. Filter. Check manometer reading and

renew filter media as indicated.

Record manometer reading. It

should be noted that checking the

filter should be carried out weekly by

maintenance staff.

1M 1. Filter. Check manometer reading and

renew filter media as indicated.

Check the pressure differential

across the filters. It should be noted

that checking the filter should be

carried out weekly by the client.

1MOther

7. Drive belts. Check tension, alignment, and

condition.

Re-tension or replace as necessary.

For detailed maintenance

procedures, see BELT DRIVES.

1M 8. Drive belts. Check tension, alignment, and

condition.

Re-tension or replace as necessary.


procedures, see Belt drives SFG

04-01

1MOther

8. Drive pulleys. Check alignment, security.12M 9. Drive pulleys. Check alignment, security.12MOther

9. Drive

couplings.

Check alignment and for excessive

clearance.

Wear is indicated by exessive

clearance and couplings should be

replaced.

12M 10. Drive

couplings.

Check alignment and for excessive

clearance.

Wear is indicated by excessive

clearance and couplings should be

replaced.

12MOther

10. Damper and

guide vane pivots

and linkages.

Lubricate lightly.3M 11. Damper and

guide vane pivots

and linkages.

Lubricate lightly.3MOther

11. Motorised

damper.

Check to see that louvres are clear

and not obstructed, couplings are

secure and that motor runs without

excessive noise or vibration.

For detailed maintenance see

MOTORS.

3M 12. Motorised

damper.

Check to see that louvers are clear

and not obstructed, couplings are

secure and that motor runs without

excessive noise or vibration.


Actuators SFG 01-01 to 01-08

3MOther

12. Heating and

cooling coils.

Check condition and clean. Check

air and water pressure drops

across coils.

Even when filters are fitted, dirt can

build up causing loss of machine

output.

12M 13. Heating and

cooling coils.

Check condition and clean. Check

air and water pressure drops across

coils. Check operation of the

heating and cooling coil in

accordance with task Heat

exchangers SFG 29-01

Even when filters are fitted, dirt can

build up causing loss of machine

output.

12MOther

13. Controls and

electrical

connections.

Check operation and condition. Calibration } Interrogation } Control

adjustment } See relevant section

12M 14. Controls and

electrical

connections.

Check operation and condition. Calibration }

Interrogation } Control

adjustment } See relevant

section

12MOther

14. Valves. Fully open and close and then reset

at the original setting.

12M 15. Valves. Fully open and close and then reset

at the original setting.

12MOther

15. Air handling

unit.

Thoroughly clean interior and check

for corrosion. On re-assembly

check for air tightness.

Include heating and cooling coils,

fan impeller and eliminator plates

and other fittings.

12M 16. Air handling

unit.

Thoroughly clean interior and check

for corrosion. On re-assembly

check for air tightness.

Include heating and cooling coils,

fan impeller and eliminator plates

and other fittings.

12MOther

16. Motors. Check:- a) condition of motor

brushes and replace if necessary,

b) clean and test windings, c) check

tightness of terminals, d) check full

load current, e) bearing wear, f)

replace lubricant in motor bearings.

This should not exceed data plate

value. Measure shaft float and end

play.

12M 17. Motors. Check all motors in accordance

with Motors SFG 39-01

This should not exceed data plate

value. Measure shaft float and end

play.

12MOther

17. Anti-vibration

mountings and

ductwork flexible

connections.

Check condition.12M 18. Anti-vibration

mountings and

ductwork flexible

connections.

Check condition.12MOther

7. Fans Check operation of fan in

accordance with the relevant

section of Fans SFG20-01 to 20-08

6MAdded

Page 13 of 614

BELTS

Page 14 of 614

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BELT DRIVES04-01 04-01 BELT DRIVES


3. Bearings.

(`Sealed for life'

bearings should

not normally

require attention).

Check for wear and lubricate at

frequencies recommended by the

manufacturer. Where oil filled,

drain, strip and clean bearing

assembly, reassemble and fill with

clean oil.

When operating in high temperature

environments e.g. above 60 o C

more frequent maintenance may be

necessary.

3M 3. Bearings.

(`Sealed for life`

bearings should

not normally

require attention).

Check for wear and lubricate at

frequencies recommended by the

manufacturer. Where oil filled,

drain, strip and clean bearing

assembly, reassemble and fill with

clean oil.

3MOther

Page 15 of 614

BOILERS/HEAT GENERATORS

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In this section on the maintenance of heat generators, the specification is aimed at establishing best

maintenance practice, but this is not intended to replace the statutory insurance inspection required by

Health and Safety regulations. The term heat generators is a generic one used within the European

Community to cover all appliances which burn fuel or convert energy to produce heat.

This section covers firstly the general requirements which are common to a group of appliances such

as hot water heat generators and then examines the maintenance needs within each group. It must

be emphasised that it is still necessary to refer to manufacturer's maintenance schedules for specific

makes of appliances.

A detailed breakdown of the contents of this section is given in the Index but the format of each

subsection is in the form of tables providing details on the item to be maintained, the frequency of

maintenance, the action to take and where appropriate informative notes about the action be taken. It

should be noted that the frequency of maintenance relates to average conditions in terms of

use and the environment in which the equipment is working. In cases where operating regimes

are severe or the environment dirty or corrosive the frequency of maintenance should be

increased to meet those conditions.

Sections include:

Hot water heat generators including condensing heat generators

Steam raising heat generators

Oil fired heat generators

Coal fired heat generators

Gas fired heat generators, direct fired, warm air heaters and radiant systems are found in HEAT

EMITTERS

Electrode heat generators

Electric heat generators

Waste/Wood Burning heat generators

Controls relating to actual pieces of equipment are covered in the appropriate tables but more

sophisticated controls are covered in the relevant sections.

Heat generator types

The term heat generator covers a wide range of energy conversion appliances which involve a heating

source, usually a fossil fuel burner or an electrical resistance element, which applies heat at one side

of a metal surface. On the other side is a heating fluid, usually water or air, which absorbs energy from

the heat source. This operation is termed heat transfer and anything which hinders that transfer

wastes energy.

In the case of hot water it can either be circulated at near atmospheric pressure or circulated at higher

pressures and temperatures above the normal boiling point. Alternatively the water can be evaporated

as steam and the steam circulated as the heating medium.

Warm air can be used as a heating medium and if it contains the products of combustion it is said to

be direct fired. Alternatively uncontaminated warm air can be provided by passing the burner gases

through a heat exchanger. In some cases the combustion gases are passed at high temperature

through radiant tubes which provide radiant heat. In most cases, air movement is fan assisted.

This section covers all the important aspects of heat generator maintenance including safety controls,

combustion, the combustion chamber and heat generator controls.

Combustion

Correct combustion entails the adequate mixing of the fuel with air to ensure that the fuel is

completely burnt without producing excessive smoke or diluting the combustion gases with excess air

both of which cause energy wastage. With all fossil fuels, insufficient air produces carbon monoxide, a

safety and health hazard, as undetected CO is poisonous and could be fatal; and a visible smoke

plume which should lead to prompt corrective action. With gas combustion, no smoke is produced

when insufficient air is used and hence the situation can go unnoticed for long periods , leading to

significant energy waste unless regular flue gas analyses are carried out and the condition corrected.

When smoke is produced it can deposit soot on the heat transfer surfaces and reduce the amount of

heat passing through the heat exchanger into the water. This in turn leads to more heat being carried

away in the flue gases. This can be detected by monitoring flue gas temperature.

In this section on the maintenance of heat generators, the specification is aimed at establishing best

maintenance practice, but this is not intended to replace the statutory insurance inspection required by

Health and Safety regulations. The term heat generators is a generic one used within the European

Community to cover all appliances which burn fuel or convert energy to produce heat.

This section covers firstly the general requirements which are common to a group of appliances such

as hot water heat generators and then examines the maintenance needs within each group. It must

be emphasised that it is still necessary to refer to manufacturer`s maintenance schedules for specific

makes of appliances.

A detailed breakdown of the contents of this section is given in the Index but the format of each

subsection is in the form of tables providing details on the item to be maintained, the frequency of

maintenance, the action to take and where appropriate informative notes about the action be taken. It

should be noted that the frequency of maintenance relates to average conditions in terms of use and

the environment in which the equipment is working. In cases where operating regimes are severe or

the environment dirty or corrosive the frequency of maintenance should be increased to meet those

conditions.

Sections include:

Hot water heat generators including condensing heat generators

Steam raising heat generators

Oil fired heat generators

Coal fired heat generators

Gas fired heat generators, direct fired, warm air heaters and radiant systems are found in Heat

emitters SFG28

Electrode heat generators

Electric heat generators

Waste/Wood Burning heat generators Controls relating to actual pieces of equipment are covered in

the appropriate tables but more sophisticated controls are covered in the relevant sections.

Heat generator types

The term heat generator covers a wide range of energy conversion appliances wh ich involve a

heating source, usually a fossil fuel burner or an electrical resistance element, which applies heat at

one side of a metal surface. On the other side is a heating fluid, usually water or air, which absorbs

energy from the heat source. This operation is termed heat transfer and anything which hinders that

transfer wastes energy.

In the case of hot water it can either be circulated at near atmospheric pressure or circulated at higher

pressures and temperatures above the normal boiling point. Alternatively the water can be evaporated

as steam and the steam circulated as the heating medium.

Warm air can be used as a heating medium and if it contains the products of combustion it is said to

be direct fired. Alternatively uncontaminated warm air can be provided by passing the burner gases

through a heat exchanger. In some cases the combustion gases are passed at high temperature

through radiant tubes which provide radiant heat. In most cases, air movement is fan assisted.

This section covers all the important aspects of heat generator maintenance including safety controls,

combustion, the combustion chamber and heat generator controls.

Combustion




safety and health hazard, as undetected CO is poisonous; and a visible smoke plume which should

lead to prompt corrective action. With gas combustion, no smoke is produced when insufficient air is

used and hence the situation can go unnoticed for long periods, leading to significant energy waste

unless regular flue gas analyses are carried out and the condition corrected.

Other

Page 17 of 614

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Poor combustion can result from:

(a) damage to or poor alignment of burner jets or pipework

(b) oil not being at the correct atomising temperature

(c) insufficient air or draught

A poor flame shape can also lead to localised overheating of the heat generator surfaces , deposition

of soot and reduced heat transfer. Cleanliness is also required on the water side of the heat exchange

surfaces. In steam raising applications, the feedwater should be treated correctly at all times to keep

internal surfaces clean and suitable provision made for the removal of solids that accumulate in the

boiler when the feedwater evaporates.

Page 18 of 614

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A fundamental element of good practice for the operator or attendant should be to carry out a visual

inspection of the heat generator at regular intervals as part of the day-to-day routine. This should

including checking for leaks and correct burner flame shape, i.e. it should be uniform in shape, 'sit' on

the burner and should not hit the walls or back of the combustion chamber.

Prior to carrying out the planned maintenance of the heat generator the following pre-maintenance

procedures should be followed:

(a) Check equipment status (i.e. on or off) and follow any specific site procedures (including

safety)

(b) Carry out a general inspection of heat generator casing for signs of damage or breakage

(c) Inspect for loose fittings or connections or any signs of leaks, smells or unusual noises

(d) Record work which will require repair, adjustment or replacement during the routine services

(e) Record existing services – (combustion/efficiency analysis should be recorded before and after

maintenance completion).

A fundamental element of good practice for the operator or attendant should be to carry out a visual

inspection of the heat generator at regular intervals as part of the day-to-day routine. This should

including checking for leaks and correct burner flame shape, i.e. it should be uniform in shape, `sit` on

the burner and should not hit the walls or back of the combustion chamber.

Prior to carrying out the planned maintenance of the heat generator the following pre-maintenance

procedures should be followed:

(a) Check equipment status (i.e. on or off) and follow any specific site procedures (including safety)<

(b) Carry out a general inspection of heat generator casing for signs of damage or breakage

(c) Inspect for loose fittings or connections or any signs of leaks, smells or unusual noises

(d) Record work which will require repair, adjustment or replacement during the routine services

(e) Record existing services – (combustion/efficiency analysis should be recorded before and after

maintenance completion).

Other

Page 19 of 614

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ATMOSPHERIC GAS BURNER - FREE STANDING BOILER05-03 05-03 ATMOSPHERIC GAS BURNER - FREE STANDING BOILER

It is essential that there must is adequate ventilation [ratio of one third low to two thirds high level] of

the boiler house for safety, plant and combustion air requirements and this must be checked with any

new contract. For detailed information reference must be made to CIBSE guides, relevant Institute of

Gas Engineers and Managers documents and appropriate British Standards.

The British Standards link is out of date - use www.bsigroup.com

Boiler room ventilation should comply with BS 5440 -2: 2009 for boilers not exceeding 70kW and BS

6644:2005 for boilers with a capacity between 70kW and 1.8MW

Undetected CO is poisonous, life threatening and also causes energy waste. Flames should be bluish

and burning in a stable manner. The burner should be quiet in operation, no excessive noise should

occur when the burner ignites or shuts down.

Consider the installation of a CO detector that complies with BS EN 50291-1:2010 and BS EN

50292:2002.

Other


1. a) Before

proceeding with

dismantling of

boiler.

Check casing for damage or

breakages. Inspect for loose fittings

or connections and any sign of

leaks.

Check for asbestos containing

material prior to dismantling any

equipment, if suspected STOP

WORK, close off the area. Have

sample Certified as safe before any

works can re-start, if asbestos, take

actions in accordance with the

Asbestos Regulations.

Refer to www.hse.gov.uk for detail.

12M 1. a) Before

proceeding with

dismantling of

boiler.




leaks.




WORK, close off the area. Take



Refer to www.hse.gov.uk.

12MOther

Pilot injection. Remove and clean. Clean by blowing through or

washing. Note: Do not use pin as

this will damage the injector.


washing. Do not use pin as this will

damage the injector.

12MOther

Burners, Gas

valve,

thermocouple and

pilot tube.

Check adjust and refit along with

main burner.

9. Burners, Gas

valve,

thermocouple and

pilot tube.


main burner.

12MOther

9. Boiler and

installation.

Open gas cock and test for gas

soundness, reconnect electrical

services. Test controls operation,

relight pilot and run up boiler.

Test flame setting, thermocouple

sensitivity and check manifold gas

pressure against manufacturer's

settings, adjust if required. If in

doubt check gas supply standing

pressure at the meter .

12M 10. Boiler and

installation.





Test flame setting, thermocouple


pressure against manufacturer`s




12MOther

10. a) Safety

check

productions of

combustion

Ensure that no products of

combustion are entering the area of

the building where the boiler is

situated.

NB - Undetected CO is poisonous,

life threatening and also causes

energy waste. Flames should be

bluish and burning in a stable

manner. The burner should be quiet

in operation, no excessive noise

should occur when the burner

ignites or shuts down. NB in

domestic premises, consider the

installation of a BS approved CO

detector.

12M 11. a) Safety

check

Combustion




situated.

The checks should be carried out in

line with the requirements of the

Gas Safety (installations and Use)

regulations

12MOther

Page 20 of 614

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11.

Documentation.

Provide written report. The report should be signed by the

servicing engineer and the

client/responsible person/clients

representative. Premature failure of

the plant will result if a satisfactory

service is not carried out. Depending

on the nature/urgency of the fault

and the type of premises this report

may be verbal. NB Gas work must

be carried out by a competent

engineer qualified as required by the

Gas Safety (Installation & Use)

Regulation.

12M 11.

Documentation.

Provide written report. The report should be signed by the





service is not carried out.

Depending on the nature/urgency of

the fault and the type of premises

this report may be verbal. Gas work

must be carried out by a competent

engineer qualified as required by the

Gas Safety (Installation and Use)

Regulations.

12MOther

12. Unsafe

installations

Recommendations If after servicing the appliance it is

considered unsafe, the

recommendation to the client is that

it must be taken out of use. If

approval for this action is refused an

appropriate label must be attached

to the appliance and a written report

must be signed by the


representative. Both the gas

supplier and a supervisor/manager

must be informed.

12M 12. Unsafe

installations












must be informed.

12MOther

Page 21 of 614

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Change

ATMOSPHERIC GAS BURNER - CONDENSING BOILER05-04 05-04 ATMOSPHERIC GAS BURNER - CONDENSING BOILER

The essential feature of a condensing boiler is that to increase the efficiency the flue gases are cooled

below their dew point with the result that water is produced which has to be removed from the system.

It is essential that there should be adequate ventilation [ratio of one third low to two thirds high level]

of the boiler house for safety, plant and combustion air requirements and this should be checked with

any new contract. For detailed information reference should be made to the CIBSE guides, relevant

Institute of Gas Engineers and Managers documents and appropriate British Standards.


below their dew point with the result that condensate is produced which has to be removed from the

flue via drainage pipework.


6644:2005 for boilers with a capacity between 70kW and 1.8MW.



occur when the burner ignites or shuts down. In domestic premises, consider the installation of a CO

detector that complies with BS EN 50291-1:2010 and BS EN 50292:2002.

Other


1. a) Before

proceeding with

dismantling of

boiler. b) Test

fire.




leaks. Record settings.

Check for asbestos prior to

dismantling any equipment, if

suspected STOP WORK, close off

the area. Have sample Certified as

safe before any works can re-start, if

asbestos, take actions in

accordance with the Asbestos

Regulations.


12M 1. a) Before

proceeding with

dismantling of

boiler. b) Test

fire.











Refer to www.hse.gov.uk..

12MOther

2. Pre-service

checks

Condensate flow

Check that there is a steady fall

back to the boiler from the flue to

allow condensate to run back. With

the boiler operating at low return,

temperature [less than 50 o C],

check that condensate flows freely

from the drain pipe.

Risk Assessment may be required.

Waste Disposal Licensing

Regulations may apply.

12M 2. Pre-service

checks

Condensate flow





temperature [less than 50 deg C],




Waste Disposal Licensing


12MOther

7. Condensate

drain pipe and

U-siphon trap.

Clean, inspect and flush.12M 7. Condensate

drain pipe and

U-siphon trap.

Clean, inspect and flush. Ensure trap contains water to act as

a seal

12MTechnical

11.Remove

burners and pilot

assembly and

baffles if fitted.

Brush all accessible flueways

thoroughly from top to bottom,

clean all deposits from the burner

box, refit baffles and flue cover -

checking cover seal. Check for

cracking and wear.

Cleaning should be through and

carried out as per the manufacturers

instructions.

12M 11.Remove

burners and pilot

assembly and

baffles if fitted.

Brush all accessible flue ways

thoroughly from top to bottom,

clean all deposits from the burner

box, refit baffles and flue cover -

checking cover seal. Check for

cracking and wear.

Cleaning should be through and

carried out as per the manufacturers

instructions.

12MLegislative







Other

Burners, Gas

valve,

thermocouple and

pilot tube.


main burner.

15. Burners, Gas

valve,

thermocouple and

pilot tube.


main burner.

12MOther

15. . Water

treatment.LOW

NOX Boilers

Check treatment regime is correct. Some condensing boilers contain

aluminium.

12M 16. Water

treatment. LOW

NOX Boilers

Check treatment regime is correct. Some condensing boilers contain

aluminium.

12MOther

Page 22 of 614

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Reason For

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16. Kanthal

bars/rods.

Inspect, clean with compressed air. If there are any signs of bending,

replace. For all condensing boilers,

manufacturers specific service

instructions take precedence.

12M 17. Kanthal

bars/rods.

Inspect, clean with compressed air. If there are any signs of bending,

replace. For all condensing boilers,

manufacturers specific service

instructions take precedence.

12MOther

17. Boiler and

installation.





Test flame setting and thermocouple



settings, adjust if required.If in doubt

check gas supply standing pressure

at the meter .

12M 18. Boiler and

installation.











12MOther

18. a) Safety

check

productions of

combustion




situated.

NB - Undetected CO is poisonous,

life threatening and also causes

energy waste. Flames should be

bluish and burning in a stable


in operation, no excessive noise

should occur when the burner ignitor

shuts down. NB in domestic

premises consider the installation of

a BS approved CO detector.

12M 19. a) Safety

check

productions of

combustion




situated.

The checks should be carried out in

line with the requirements of the

Gas Safety (installations and Use)

regulations

12MLegislative

19.

Documentation.

Provide written report. The report must be signed by the





service is not carried out, by a

competent engineer qualified as

required by the Gas Safety

Regulations. Depending on the

nature/urgency of the fault and the

type of premises this report may be

verbal.

12M 19.

Documentation.












verbal.

12MOther

Page 23 of 614

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COAL FIRED BOILERS Bunkers and Conveyors.05-05 05-05 COAL FIRED BOILERS Bunkers and Conveyors.

The burning of coal is a complex operation involving the storage, handling and combustion of solid

material, plus the handling, disposal of gaseous and solid waste. The materials are abrasive with the

wear and tear on mechanical plant considerable, hence regular maintenance is vital to ensure

continuous working and a clean environment. The maintenance of each section of the coal burning

operation is examined in sequence.

WARNING. A risk assessment and method statement must be undertaken before entering any

confined space such as a hopper, flue chamber or boiler to ensure that there is adequate

ventilation and an absence of any fumes or flue gases.

The burning of coal is a complex operation involving the storage, handling and combustion of solid

material, plus the handling, disposal of gaseous and solid waste. The materials are abrasive with the

wear and tear on mechanical plant considerable, hence regular maintenance is vital to ensure


operation is examined in sequence.

WARNING. A risk assessment and method statement must be undertaken in accordance

with the Confined Spaces Regulations, before entering any confined space such as a hopper, flue

chamber or boiler to ensure that there is adequate ventilation and an absence of any fumes or flue

gases.

Other


1. Operational

status.

Check and isolate from electricity

supply, remove fuses if used.

1M 1. Operational

status.

Check and isolate and Lock Off

from electricity supply, remove

fuses if used.

Depending on the Establishment, a

Permit to Work system may be in

operation. The Authorised Person

should be approached for the issue

of the permit.

1MOther

Page 24 of 614

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Reason For

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COAL FIRED BOILERS - Coal storage handling and feed mechanisms,

automatic ash removal (where fitted)

05-06 05-06 COAL FIRED BOILERS - Coal storage handling and feed mechanisms,

automatic ash removal (where fitted)

The burning of coal is a complex operation involving the storage, handling, combustion of solid

material, together with the handling, disposal of gaseous and solid waste. The materials are abrasive

and the wear and tear on mechanical plant considerable, hence regular maintenance is vital to ensure


operation is examined in sequence.(See also Motors)


confined space such as a hopper, flue chamber or boiler to ensure that there is adequate






operation is examined in sequence.(See also Motors SFG 39)

WARNING. A risk assessment and method statement must be undertaken before entering

any confined space such as a hopper, flue chamber or boiler to ensure that there is adequate


Other


1. Operational

status.


supply. Remove fuses, if used.

1M 1. Operational

status.


from electricity supply. Remove

fuses, if used.





of the permit.

1MOther

5.Pneumatic

system. (Applies

to both coal feed

and ash removal,

where fitted).

Inspect and replace items listed

under notes. Check for air

tightness.

(a) air seals on each outlet cyclone,

(b) clean blades of fan, (c) ensure

timing sequence, (d) check 'bags',

(e) check bag shaker and lubricate

as appropriate . Note: It is essential

to maintain air tightness on

pneumatic systems otherwise the

coal feed cannot be maintained,

output is reduced and energy

wasted.

3M 5.Pneumatic

system. (Applies

to both coal feed

and ash removal,

where fitted).



tightness.



timing sequence, (d) check `bags`,


as appropriate . It is essential to

maintain air tightness on pneumatic

systems otherwise the coal feed

cannot be maintained, output is

reduced and energy wasted.

3MOther

Page 25 of 614

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COAL FEED MECHANISMS - Under feed stokers05-07 05-07 COAL FEED MECHANISMS - Under feed stokers







confined space such as a hopper, flue chamber or boiler to ensure that there is adequate ventilation

and an absence of any fumes or flue gases.

Added


1. Operational

status.



Cables should be checked for

insulation breakdown and the earth

continuity checked.

6M 1. Operational

status.



fuses, if used.





of the permit.

6MOther

Page 26 of 614

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COAL FEED MECHANISMS - Chain grate stokers05-08 05-08 COAL FEED MECHANISMS - Chain grate stokers

WARNING – A RISK ASSESSMENT AND METHOD STATEMENT MUST BE UNDERTAKEN

BEFORE AN OPERATOR/ENGINEER ENTERS COAL SIL0.






WARNING. A risk assessment and method statement must be undertaken before entering

any confined space such as a hopper, flue chamber or boiler to ensure that there is adequate


Other


1. Operational

status.



12M 1. Operational

status.

Check and isolate and Lock off


fuses, if used.





of the permit.

12MOther

4. Drain sump. Ensure excess water can be

drained off.

12M 4. Drain sump. Ensure excess water can be

drained off.

Clean and unblock drain as

necessary

12MTechnical

Check coal auger supports. Repair or replace as necessary. a) Check coal auger supports. Repair or replace as necessary.12MOther

Remove augers and check for wear

and distortion.

b) Remove augers and check for wear

and distortion.

12MOther

Reassemble and recoat coal tube. Use bituminised sealant or similar

protective coating.

c) Reassemble and recoat coal tube. Use bituminised sealant or similar

protective coating.

12MOther

Page 27 of 614

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Reason For

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ASH HANDLING SYSTEM05-09 05-09 ASH HANDLING SYSTEM







confined space such as a hopper, flue chamber or boiler to ensure that there is adequate ventilation

and an absence of any fumes or flue gases.

Added


2. Ash line valve. Check operation and wear on

seals.

12M 2. Ash line valve. Check and isolate and Lock off


fuses, if used. Check operation and

wear on seals.

12MTechnical

Spray jets. Check operation.3M Spray jets. Check operation and adjust nozzles

for correct spray pattern if

necessary

3MTechnical

Page 28 of 614

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Reason For

Change

BLOWN GAS BURNER CONDENSING BOILER05-10 05-10 BLOWN GAS BURNER CONDENSING BOILER



any new contract. For detailed information reference should be made to the CIBSE guides, relevant

Institution of Gas Engineers and Managers documents and appropriate British Standards .






detector that complies with BS EN 50291-1:2010 and BS EN 50292:2002..

Other


1. Check

Operation.

Note any visible defects.12M 1. Check

Operation.

Note any visible defects. Check for asbestos containing







12MTechnical

3. Gas electrical

systems.

Check that all are in accordance

with current Codes of Practice.

12M 3. Gas, electrical

and ventilation

systems .



Local electrical isolator should be

fitted. Supply to the boiler must be

direct, i.e. not fed through a time

switch.

12MTechnical

4. Pre service

checks -

Condensate flow.





temperature [less than 50 ºC],



Risk Assessment may be required

Waste Disposal Regulations may

apply.

12M 4. Pre service

checks -

Condensate flow.

Where applicable, Check that there

is a steady fall back to the boiler

from the flue to allow condensate to

run back. With the boiler operating

at low return, temperature [less

than 50 deg C], check that

condensate flows freely from the

drain pipe.

Risk Assessment may be required


apply.

12MTechnical

5. Isolate from

electricity and gas

supply.

Switch off, remove fuses and turn

off oil supply at main cock.

Before starting any dismantling of

equipment it is essential for safety

reasons that the plant be isolated

from incoming services.

12M 5. Isolate from

electricity and gas

supply.

Switch off, remove fuses and/or

lock off and turn off gas supply at

main cock.





12MTechnical

. b]Boiler tube

module.

Clean and descale module in

accordance with manufacturers

instructions.

Always follow recommendations

from manufacturer. Note: Waste

Disposal Regulations may apply

48M 13 b]Boiler tube

module.



instructions.


from manufacturer. Waste Disposal

Regulations may apply

48MOther

17. Unsafe

installations.

Recommendations If after servicing the boiler is

considered unsafe the








representative with the gas supplier

and a supervisor/manager informed.

12M 17. Unsafe

installations.












must be informed.

12MTechnical

Page 29 of 614

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Change

BLOWN GAS BURNER MODULAR BOILER05-11 05-11 BLOWN GAS BURNER MODULAR BOILER

Can comprise several modules, each having separate controls. Each module must be isolated and

work carried out consecutively.



any new contract. For detailed information reference should be made to the CIBSE guide, relevant

Institution of Gas Engineers and Managers documents and appropriate British Standards .

Can comprise several modules, each having separate controls. Each module must be isolated and

work carried out consecutively.







Other


1. Check

Operation.

Note any visible defects.12M 1. Check

Operation.








12MTechnical

3. Gas electrical

systems.




and ventilation

systems .



12MTechnical

5. Isolate from

electricity and gas

supply.


off oil supply at main cock.





12M 5. Isolate from

electricity and gas

supply.

Switch off, remove fuses and/or

lock off and turn off gas supply at

main cock.





12MTechnical

12. Boiler flue

ways and

connecting flues.

Open and remove all soot and

scale by brushing and/or vacuum.

Reseal, check for air leaks,make

good as required.

12M 12. Boiler flue

ways and

connecting flues.

Open and remove all soot and

scale by brushing and/or vacuum.

Reseal, check for air leaks, make

good as required.

12MTechnical

b] Boiler tube

module.



instructions.


from manufacturer. Note: Waste

Disposal Regulations. may apply

48M 13. b] Boiler tube

module.



instructions.



Regulations. may apply

48MOther

Page 30 of 614

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Reason For

Change

FORCED DRAUGHT GAS CONDENSING BOILER05-12 05-12 FORCED DRAUGHT GAS CONDENSING BOILER




of the boiler houses for safety, plant and combustion air requirements and this should be checked with

any new contract. For detailed information reference should be made to the CIBSE guide, relevant

Institute of Gas Engineers documents and appropriate British Standards.










Technical


b) Test fire. Record settings. Check for asbestos prior to

dismantling and equipment, if






Regulations

b) Test fire. Record settings. Check for asbestos containing







12MOther

2. Pre-service

checks.

Condensate flow.










apply.

12M 2. Pre-service

checks.

Condensate flow.










apply.

12MOther

17. a) Safety

check Gas.




situated.

NB Undetected CO is life

threatening (poisonous) and also

causes energy waste. Flames

should be bluish and burning in a

stable manner. The burner should

be quiet in operation, no excessive

noises should occur when the

burner ignitor shuts down.

12M 17. a) Safety

check Gas.




situated.

Undetected CO is life threatening

(poisonous) and also causes energy

waste. Flames should be bluish and

burning in a stable manner. The

burner should be quiet in operation,

no excessive noises should occur

when the burner ignitor shuts down.

12MOther

18. Unsafe

installations.

Recommendations. If after servicing the boiler is









representative and both the gas


informed.

12M 18. Unsafe

installations.

Recommendations. If after servicing the boiler is








client/responsible person



informed.

12MOther

Page 31 of 614

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Reason For

Change

FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER05-13 05-13 FORCED DRAUGHT [PRESSURE JET] OIL CONDENSING BOILER






Undetected CO is poisonous, life threatening and also causes energy waste. The burner should be

quiet in operation, no excessive noise should occur when the burner ignites or shuts down. In

domestic premises, consider the installation of a CO detector that complies with BS EN 50291-1:2010

and BS EN 50292:2002.

Added


1. a) Before

proceeding with

dismantling of

boiler.




leaks.

12M 1. a) Before

proceeding with

dismantling of

boiler.


breakages. Inspect for loose

fittings or connections and any sign

of leaks.








12MOther

2. Pre-service

checks.










apply.

12M 2. Pre-service

checks.










apply.

12MOther

7. Isolate from

electricity and gas

supply.


off gas supply at main cock.

Before starting and dismantling of




6M 7. Isolate from

electricity and oil

supply.


off oil supply at main valve.

Before starting and dismantling of




6MOther

8. Jet arm

assembly.

Remove, clean combustion head,

ignitor electrodes and inspect HT

leads.

6M 8. Jet arm

assembly.

Remove, clean combustion head,

ignition electrodes and inspect HT

leads.

6MOther

11. Motor and

fan.

Remove, clean and lubricate as

required, clean fan scroll.

Inspect oil pump flexible drive

coupling before reassembly.(See

also MOTORS)

6M 11. Motor and

fan.

Remove, clean and lubricate as



coupling before reassembly.(See

also Motors SFG 39)

6MOther

23.

Recommendation

Provide written report which should

be signed by the service engineer

and kept by client.

Premature failure and excessive fuel

costs will result if satisfactory

service is not carried out. All service

and maintenance must be carried

out by a registered engineer in

accordance with Health and Safety

requirements. All service and

maintenance works must be carried

out by a competent engineer in

accordance with BS Codes of

Practice for oil firing.

6M 23.

Recommendation

Provide written report which should


and kept by client.





out by a registered engineer in

accordance with Health and Safety

requirements. All service and

maintenance works must be carried

out by a competent engineer in

accordance with BS Codes of

Practice (www.bsi-global.com) for

oil firing.

6MOther

Page 32 of 614

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Change

BOILERS MTHW UP TO 120 oC (Wrong Symbol - Change)05-14 05-14 BOILERS MTHW UP TO 120 oC

Applies to boilers manufactured by casting or fabrication Applies to boilers manufactured by casting or fabrication.





occur when the burner ignites or shuts down.

Other


1. Check

operation, in

particular safety

controls (prv).

Note any visible defects. Ensure system is full of water and

the circuits are open. It is essential

for low water content boilers that

flow rates can be maintained at or

above manufacturers recommended

levels.

12M 1. Check

operation, in

particular safety

controls (prv).








It is likely that a Permit to Work will

be required from the Authorised

Person before any works can be

undertaken on a pressurised system

Ensure system is full of water and

the circuits are open. It is essential

for low water content boilers that

flow rates can be maintained at or

above manufacturers recommended

levels.

12MTechnical

2. Efficiency

check.

Start up system and carry out tests. On larger systems efficiency tests

should be carried out on a regular

basis to monitor performance. The

test should include smoke, draught

chamber and flue, flue temperature,

fuel input and gas analysis including

carbon monoxide.

12M 2. Efficiency

check.

Start up system and carry out tests.12MTechnical

Thermostats,

pressure sensors

& controls, altitude

gauges, vacuum

breaks.

3. Thermostats,

pressure sensors

& controls, altitude

gauges, vacuum

breaks.

Check for correct operation and

settings.

12MTechnical

3. Thermostats,

vacuum breaks.


settings.

12M Deleted

4. Electrical

services.

Shut down, disconnect or remove

fuses.

Locate isolation switch, if not in

accordance with IEE regulations

report to building owner.

12M 4. Electrical

services.

Shut down, disconnect and lock off

or remove fuses.

Local electrical isolator should be


direct i.e. not fed through a time

switch.

12MTechnical

Page 33 of 614

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Change

MULTIPLE BOILERS - sequence controls05-15 05-15 MULTIPLE BOILERS - sequence controls

All notes referring to sequence controls apply to individual boilers (not burner modules) in multiple

installations.

All notes referring to sequence controls apply to individual boilers (not burner modules) in multiple

installations.

This task should be issued with the relevant boiler maintenance task

Other


7. Boiler shunt

pump.

Confirm operation. Is there a water proving circuit?

Check operation if part of sequence

controls. See PUMPS maintenance.

12M 7. Boiler shunt

pump.

Confirm operation. Is there a water proving circuit?

Check operation if part of sequence

controls. See Pumps SFG 45-02

12MTechnical

Page 34 of 614

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BOILER CONTROLS - Single boiler: on/off05-16 05-16 BOILER CONTROLS - Single boiler: on/off

Note: On/Off overall control can be remote from the boiler plant.

Certain common maintenance procedures should be carried out for all controls. These are: -

1. All common items, e.g. thermostats and the like, that have switching contacts – where they can be

seen ensure contacts make and break easily and that there is no arcing or pitting.

2. Inspect thermostat phial and capillaries for mechanical damage.

3. Inspect thermostat pockets for corrosion and leakage.

4. Ensure immersion thermostats are secure in their pockets (and that the sensor is in contact with the

end of the pocket and covered with heat conductive compound).

5. Inspect motorised valves for leakage and damage to linkage.

For more detailed information regarding the maintenance of motorised valves, checking of gland

seals, stroking, etc. refer to relevant section.

On/Off overall control can be remote from the boiler plant.

Certain common maintenance procedures should be carried out for all controls. These are: -

1. All common items, e.g. thermostats and the like, that have switching contacts – where they can be

seen ensure contacts make and break easily and that there is no arcing or pitting.




end of the pocket and covered with heat conductive compound).

5. Inspect motorised valves for leakage and damage to linkage.



Other


2. Time switch. Check operation. Confirm time

settings.

Time of day. (Keep setting at GMT

all year unless specifically requested

by client.) Day of week. Manual

override.

12M 2. Time switch. Check operation. Confirm time

settings.

Time of day. (Keep setting at GMT

all year unless specifically

requested by client.) Day of week.

Manual override.

6MOther

4. Room

thermostat.

Check operation. Confirm set point. Ensure correct location and no air

movement restrictions. Advise client

of any faults.

12M 4. Room

thermostat.

Check operation. Confirm set

point. Ensure correct location and no air

movement restrictions. Advise client

of any faults.

12MTechnical

Page 35 of 614

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Reason For

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STEAM BOILERS Pre-maintenance check.05-19 05-19 STEAM BOILERS Pre-maintenance check.


1. Status. Check operating status. Before proceeding with

maintenance programme check with

client that boiler can be taken

off-line.

12M 1. Status. Check operating status. Before proceeding with

maintenance programme check with

client that boiler can be taken

off-line.

These works to be carried out in

accordance with the Pressure

Systems Safety Regulations 2000

and Safe Systems of Work

12MLegislative

6. Shut down. Shut off and isolate steam, water,

fuel and electrical services.

Purge fuel lines and vent boiler to

ensure safe conditions.

12M 6. Shut down. Shut off and isolate steam, water,

fuel and electrical services.

Purge fuel lines and vent boiler to

ensure safe conditions. Steam line

should be isolated with either a two

separate valves or a single valve

and spade.

12MTechnical

7. Ventilation. Check that ventilation fans and

louvres are functioning properly.

Check that there is adequate

ventilation in the boiler house and

the conditions comply with the

relevant regulations and standards.

12M 7. Ventilation. Check that ventilation fans and

louvers are functioning properly.

Check that there is adequate

ventilation in the boiler house and

the conditions comply with the

relevant regulations and standards.

Boiler room ventilation should

comply with BS 5440 -2: 2009 for

boilers not exceeding 70kW and BS

6644:2005 for boilers with a

capacity between 70kW and 1.8MW

12MTechnical

Page 36 of 614

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STEAM BOILERS Maintenance schedule.05-20 05-20 STEAM BOILERS Maintenance schedule.

This is generally carried out at the same time as the Annual Statutory Insurance Inspection . The yearly tasks shown below are generally carried out at the same time as the Annual Statutory

(Insurance) Inspection.

Check for asbestos containing material prior to dismantling any equipment, if suspected STOP

WORK, close off the area. Take actions in accordance with the Asbestos Regulations.


Other


1. Boiler

flueways,

combustion

chamber and

connecting flue.

Open, remove by brushing and/or

vacuum all soot and scale.

Soot, ash and other fouling deposits

impede heat transfer thus wasting

energy and putting up costs.

12M 15. Boiler

flueways,

combustion

chamber and

connecting flue.






12MLegislative

2. Fire tubes. Open boiler end doors and clean

fire tubes by brushing or rotary

scouring equipment.

In multipass boilers it is important to

clean all passes.

12M 16. Fire tubes. Open boiler end doors and clean


scouring equipment.


clean all passes.

12MOther

3. Refractory

linings.

Check condition and report.12M 17. Refractory

linings.

Check condition and report.12MOther

4. Boiler

flueways, doors

and chamber.

Reseal, check for air leaks, seal as

necessary.

12M 18. Boiler

flueways, doors

and chamber.


necessary.

12MOther

5. Flue. Carry out smoke test.12M 19. Flue. Carry out smoke test.12MOther

6. Waterside. Remove manholes, clean out scale

and residues. Replace, reseal and

ensure bolts are tight.

If there are considerable deposits of

sludge and scale, this indicates poor

water treatment which if allowed to

continue will lead to boiler failure

and energy wastage. Waste

Disposal Regulations may apply.

12M 20. Waterside. Remove manholes, clean out scale








Disposal Regulations may apply.

12MOther

7. Boiler. Refill, reconnect and bring on line. Refit casing if necessary and

thoroughly clean down.

12M 21. Boiler. Refill, reconnect and bring on line. Refit casing if necessary and


12MOther

8.

Instrumentation

and flame

monitoring.

Check for operation and accuracy. Recalibrate and reset if necessary.12M 22.

Instrumentation

and flame

monitoring.

Check for operation and accuracy. Recalibrate and reset if necessary.12MOther

9. Combustion

check.

Bring up to full load and carry out

tests.

On larger systems combustion tests





carbon dioxide, oxygen and carbon

monoxide.

12M 23. Combustion

check.


tests.







monoxide.

12MOther

10. Blow down

tank.

For maintenance procedures see

SANITARY & WASTE WATER

PLUMBING Interceptors .

HSE document PM60 applies.12M 24. Blow down

tank.


Sanitary and waste water plumbing

SFG 48-04

HSE document PM60 applies.12MOther

Self-monitoring

controls

Added

Page 37 of 614

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1. Water gauge

test

Record time test carried out, log

results with the operator`s name,

date of test plus any corrective

action taken.

1DAdded

2. Water level left

hand gauge

Manually blow down Record time test carried out.1DAdded

3. Water level right

hand gauge

Manually blow down Record time test carried out.1DAdded

4. Water level

control

Test low water level cut-out and

lock-out

At no time during a test should the

water be lowered to the extent that it

disappears from the gauge glass.

Record time test carried out

1DAdded

5. Feed pump

start/stop or

modulation

Check operation. Record time test carried out.1DAdded

6. Pressure

reading

Record pressure gauge reading Record time test carried out.1DAdded

7. Feed water and

condensate check

Check the feed tank level is

adequate and there are no

contaminants. Check that the

chemical dose metering device is

functioning and there are adequate

chemical stocks in the tanks. Check

that the in-house routine sample

results are within their given

parameters provided by the water

treatment specialist and take

remedial action when necessary.

Check the temperature is above the

required level for the treatment

doses specified for oxygen

scavenging.




action taken.

1DAdded

8. TDS water test Carry out TDS water quality test,

record the result and make

adjustments where necessary.

Record time test carried out.1DAdded

9. pH water test Carry out pH water quality test,




10. Blow down record quantity of water blown

down.


11. Flame failure Test flame failure lock-out.

This may not be present on non self

monitoring boilers

Record time test carried out.1WAdded

12. Failure to

ignite

Test failure to ignite lock out. Record time test carried out.1WAdded

Page 38 of 614

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13. Water level 1st Test by lowering water level to 1st

low water level, by evaporation and

controlled blowdown, and check

burner locks out and the alarm is

sounded.

Discharge temperature to drain

should not exceed permissible

limits.

Record time test carried out.




1WAdded

14. Water level

2nd

Test by lowering water level to 2nd




sounded.



limits.





1WAdded

Page 39 of 614

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ELECTRIC BOILERS05-21 05-21 ELECTRIC BOILERS

These boilers provide heat to radiator heating systems. Electricity supply can be off-peak/on-peak or a

combination of both.

These boilers provide heat to LTHW and Domestic Hot Water systems. Electricity supply can be

off-peak/on-peak or a combination of both.




Technical


1. Isolation from

electricity supplies.

Switch off. Remove fuses from both

supplies.

The boilers have two supplies. The

permanent large capacity supply

and the restricted hours signal

supply. Report to the client if not

capable of isolation.

12M 1. Isolation from


Switch and lock off. Remove fuses

from both supplies.

The boilers have two supplies. The

permanent large capacity supply

and the restricted hours signal

supply. Report to the client if not

capable of isolation.

12MTechnical

3. Heavy current

connection in the

control box.

Remove control box cover. Check

all heavy current connection for

tightness and signs of over heating,

also check element relay contacts

for damage.

See also MOTORS12M 3. Heavy current

connection in the

control box.

Remove control box cover. Check

all heavy current connection for

tightness and signs of over heating,

also check element relay contacts

for damage.

12MTechnical

5. Fan cooling air

duct.

Remove button front casing clean

duct through casing, remove also

the rear end fan motor which is

exposed when the casing is

removed.

Report if fan motor or pump are

noisy. Advise the customer that the

louvres on the outside of the casing

should be vacuumed at intervals if

the environment of the boiler is

unclean.

12M 5. Fan cooling air

duct.

Remove button front casing clean

duct through casing, remove the

rear end fan motor which is

exposed when the casing is

removed.

Report if fan motor or pump are

noisy. Advise the customer that the

louvers on the outside of the casing

should be vacuumed at intervals if

the environment of the boiler is

unclean.

12MTechnical

Page 40 of 614

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ELECTRODE BOILERS05-22 05-22 ELECTRODE BOILERS

Note:In hard water areas maintenance may require to be carried out more frequently.

BEWARE: - High water conductivity in the boiler circulated water can damage the boiler pressure

vessel, only work within the boiler manufacturers values of conductivity.

In hard water areas maintenance may require to be carried out more frequently.

BEWARE: - High water conductivity in the boiler circulated water can damage the boiler pressure

vessel, only work within the boiler manufacturers values of conductivity. See manufacturers

information on recommended values.




Technical


b) Porcelain

insulators.

Examine for defects and replace if

necessary. Clean with non-abrasive

material.

12M Deleted

5. Feed solenoid

(if fitted).

Clean solenoid, manifold and

strainer.

Modern boilers have the load control

driven by an electric motor. See

MOTORS.

12M 5. Feed solenoid

(if fitted).


strainer.


driven by an electric motor. (See

also Motors SFG 39)

12MOther

7. Boiler

circulated water.

Test for correct conductivity at

20/25 ºC.

This is to be within the boiler makers

recommendation.

3M 7. Boiler

circulated water.

Test for correct conductivity at

20/25 deg C.

This is to be within the boiler makers

recommendation.

3MOther

Page 41 of 614

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BOILERS LTHW UP TO 95ºC05-23 05-23 BOILERS LTHW UP TO 95ºC

Applies to boilers manufactured by casting or fabrication. Applies to boilers manufactured by casting or fabrication.




Technical


4. Electrical

services.


fuses.




12M 4. Electrical

services.


fuses.




12MTechnical

9. Flue. Carry out smoke test. Only if flue problem is suspected .12M 9. Flue. Carry out smoke test. Only if flue blockage is suspected .12MTechnical

Page 42 of 614

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BOILERS - FIRE AND SAFETY CIRCUITS05-24 05-24 BOILERS - FIRE AND SAFETY CIRCUITS

Is the plant safe? It should be noted that fire prevention and fire alarms are not included in the scope

of this document. . Any persons working on such equipment should be registered with the Loss

Prevention Council or should be the Manufacturer's nominated fire prevention contractor. It is

essential that the operation of all indicator lights should be checked regularly and that any

malfunctions should be corrected as soon as possible. Boiler and Plant Room should not contain

loose combustible materials.

Is the plant safe? It should be noted that fire prevention and fire alarms are not included in the scope

of this document. Any persons working on such equipment should be registered with the Loss

Prevention Council (www.bre.co.uk/frs) or should be the Manufacturer`s nominated fire prevention

provider. It is essential that the operation of all indicator lights should be checked regularly and that

any malfunctions should be corrected as soon as possible. Boiler and Plant Room should not contain

loose combustible materials.

Other

Page 43 of 614

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WASTE AND WOOD BURNING APPLIANCES (including boilers) - Fire And

Boiler Safety Circuits

05-25 05-25 WASTE AND WOOD BURNING APPLIANCES (including boilers) - Fire And

Boiler Safety Circuits

Note : Regular cleaning of flues is essential when burning waste and wood because tars and other

residues may not be fully burned in the combustion chamber and condensation of combustion

products can lead to blockage and fires in the flues

Regular cleaning of flues is essential when burning waste and wood because tars and other residues

may not be fully burned in the combustion chamber and condensation of combustion products can

lead to blockage and fires in the flues




Technical


fusible links,

interconnecting

tension wire and

pulleys.

Inspect.3M fusible links,

interconnecting

tension wire and

pulleys.

Inspect. Replace fusible links if damaged3MTechnical

4. Smoke/heat

detection.

Check operation. Refer to Code of Practice BS 5839.3M 4. Smoke/heat

detection.

Check operation. Refer to Code of Practice BS 5839

and Fire alarm system SFG 22-01

3MOther

Page 44 of 614

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Reason For

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WASTE AND WOOD BURNING APPLIANCES (including boilers) -

Combustion Chamber

05-26 05-26 WASTE AND WOOD BURNING APPLIANCES (including boilers) -

Combustion Chamber




Added


(b) Pneumatic. Inspect and check for wear. In pneumatic systems wear mainly

occurs on the bends and wear

plates are usually fitted. Any badly

worn ones should be replaced.

3M (b) Pneumatic. Inspect and check for wear. In pneumatic systems wear mainly

occurs on the bends and wear

plates are usually fitted. Any badly

worn plates should be replaced.

3MOther

3. Ash removal. Inspect for wear and where

operation automatic reset controls.

3M 3. Ash removal. Inspect for wear and where

operation automatic reset controls.




3MLegislative

4. Automatic

ignition.

Clean and check operation and

reset.

Refer to Code of Practice BS 5839.3M 5. Automatic

ignition.

Clean and check operation and

reset.

Refer to Code of Practice BS 5839.3MOther

5. Combustion

check.

Carry out and adjust primary and

secondary and tertiary (if any) air

for optimum combustion.

Because of the variable nature of

the fuel allowance for some excess

air is necessary. With starved air

(two phased combustion) tests

should be carried out after each

stage and should include CO.

3M 6. Combustion

check.

Carry out and adjust primary and

secondary and tertiary (if any) air

for optimum combustion.

Because of the variable nature of

the fuel allowance for some excess

air is necessary. With starved air

(two phased combustion) tests

should be carried out after each

stage and should include CO.

3MOther

6. General. Check all fuel supply valves for free

operation.

Ensure that each fuel supply valve is

complete with its own wheel or key.

3M 7. General. Check all fuel supply valves for free

operation.

Ensure that each fuel supply valve

is complete with its own wheel or

key.

3MOther

4. Refractory

linings.

Check condition and report.3MAdded

Page 45 of 614

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Reason For

Change

WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if

fitted)

05-27 05-27 WASTE AND WOOD BURNING APPLIANCES (including boilers) - BOILER (if

fitted)




Added

Page 46 of 614

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Reason For

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Atmospheric Gas Burner Boiler - Small and/or wall hung for domestic/light

commercial installation

05-28 05-28 Atmospheric Gas Burner Boiler - Small and/or wall hung for domestic/light

commercial installationTitle NotesActionFQTitle FQ Action Notes

1. a) Before

proceeding with

dismantling of

boiler.





Check for asbestos prior to

dismantling any equipment, if






Regulations.

Refer to www.hse,gov.uk for detail.

12M 1. a) Before

proceeding with

dismantling of

boiler.












12MOther

b) Check firing. Observe the main burner. Use a

combustion analyzer to measure

CO & CO 2 content of flue gas.

Check Gas pressure, Record

settings.

Dark mauve flame and excessive

lifting off indicate poor combustion.

12M b) Check firing. Observe the main burner. Use a

combustion analyser to measure

CO & CO 2 content of flue gas.

Check Gas pressure, Record

settings.



12MOther

2. Gas electrical

and ventilation

systems.



Local electrical isolator must be



switch.

12M 2. Gas electrical

and ventilation

systems.






switch.

12MOther







Other

Burners, Gas

valve,

thermocouple and

pilot tube.


main burner.

9. Burners, Gas

valve,

thermocouple and

pilot tube.


main burner.

Other

9. Boiler and

installation.











12M 10. Boiler and

installation.











12MOther

10. a) Safety

check Gas




situated.

NB - Undetected CO is life


causes energy waste. This can be

achieved in domestic premises

consider the installation of a BS

approved CO detector. Flames




noise should occur when the burner

ignitor shuts down. NB in domestic

premises consider the installation of

a BS approved CO detector

12M 11. a) Safety

check Gas




situated.



waste. Flames should be bluish and



no excessive noise should occur

when the burner ignition shuts

down. In domestic premises


(www.bsi-global.com) approved CO

detector

12MOther

Page 47 of 614

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Reason For

Change

11.

Documentation.




representative . Premature failure of








verbal.

12M 12.

Documentation.




representative . Premature failure of








verbal.

12MOther

12. Unsafe

installations

Recommendations If after servicing the appliance is











informed.

12M 13. Unsafe

installations












informed.

12MOther

Page 48 of 614

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Reason For

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COMBINATION ATMOSPHERIC BURNER GAS BOILER05-29 05-29 COMBINATION ATMOSPHERIC BURNER GAS BOILER


1. a) Before

proceeding with

dismantling of

boiler.

Check Central Heating system for

leaks.

Flame must cover all flame parts

and be light blue in colour.

12M 1. a) Before

proceeding with

dismantling of

boiler.


leaks.



12MOther

b) Test firing. Set appliance to DHW highest flow

rate to observe the main burner.

Use a combustion analyzer to

measure CO and CO 2 content of

flue gas. Check Gas pressure,

Water volume and pressure.

Record settings.



If appliance is fitted in a hard water

area (above 200 ppm), a suitable

water treatment device should be

fitted.

12M b) Test firing. Set appliance to DHW highest flow


Use a combustion analyser to



Water volume and pressure.

Record settings.






fitted.

12MOther

2. Gas electrical

and ventilation

systems.






switch.

12M 2. Gas electrical

and ventilation

systems.






switch.

12MOther

Burners, Gas

valve,

thermocouple and

pilot tube.


main burner.

11. Burners, Gas

valve,

thermocouple and

pilot tube.


main burner.

12MOther

11. Boiler and

installation.








settings, adjust if required.If in doubt

check gas supply standing pressure

at the meter.

12M 12. Boiler and

installation.










pressure at the meter.

12MOther

12. a) Safety

check Gas




situated.






approved CO detector. Flames must

be bluish and burning in a stable


in operation, with no excessive;


ignitor shuts down.

12M 13. a) Safety

check Gas




situated.



waste. This can be achieved in

domestic premises consider the


detector. Flames must be bluish and



with no excessive; noise should

occur when the burner ignition shuts

down.

12MOther

13.

Documentation.












verbal .

12M 14.

Documentation.












verbal .

12MOther

Page 49 of 614

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Reason For

Change

14. Unsafe

installations












informed.

12M 15. Unsafe

installations












informed.

12MOther

Page 50 of 614

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Reason For

Change

ATMOSPHERIC GAS BURNER/CONDENSING COMBINATION BOILER05-30 05-30 ATMOSPHERIC GAS BURNER/CONDENSING COMBINATION BOILER











Other


1. a) Before

proceeding with

dismantling of

boiler.


leaks.



12M 1. a) Before

proceeding with

dismantling of

boiler.


leaks.



12MOther

b) Test firing. Set appliance to DHW highest flow


Use a combustion analyzer to



Water volume with the boiler

operating at low return

temperatures (less than 50 ºC)


from the drain pipe. Record

settings.






fitted.

12M b) Test firing. Set appliance to DHW highest flow


Use a combustion analyser to



Water volume with the boiler

operating at low return

temperatures (less than 50 ºC)


from the drain pipe. Record

settings.






fitted.

12MOther

2. Gas electrical

and ventilation

systems.






switch.


and ventilation

systems.






switch.

12MOther

Burners, Gas

valve,

thermocouple and

pilot tube.


main burner. Check that

condensate flows freely at low

boiler return temperatures.

12. Burners, Gas

valve,

thermocouple and

pilot tube.


main burner. Check that

condensate flows freely at low

boiler return temperatures.

0MOther

12. Boiler and

installation.











12M 13. Boiler and

installation.











12MOther

13. a) Safety

check Gas




situated.






approved CO detector. Flames





ignitor shuts down.

12M 14. a) Safety

check Gas




situated.



waste. This can be achieved in

domestic premises consider the


detector. Flames should be bluish

and burning in a stable manner.

The burner should be quiet in

operation, no excessive noise

should occur when the burner

ignition shuts down.

12MOther

Page 51 of 614

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Reason For

Change

14.

Documentation.












verbal.

12M 15.

Documentation.












verbal.

12MOther

15.Unsafe

installations












informed.

12M 16.Unsafe

installations












informed.

12MOther

Page 52 of 614

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Reason For

Change

AIR TO WATER HEAT PUMP05-31 05-31 AIR TO WATER HEAT PUMP


1. Status. Isolate electrically. Note: Isolation of electrical

equipment should be carried out in

accordance with HASAWA

requirements. THIS LINK IS

WRONG , SHOULD BE -

www.hse.gov.uk

6M 1. Status. Isolate electrically. Isolation of electrical equipment

should be carried out in accordance

with HASAWA (www.hse.gov.uk)

6MOther

Page 53 of 614

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Reason For

Change

WATER TO WATER HEAT PUMP05-32 05-32 WATER TO WATER HEAT PUMP





requirements.

6M 1. Status. Isolate electrically. Isolation of electrical equipment

should be carried out in accordance

with HASAWA (www.hse.gov.uk)

requirements.

6MOther

Page 54 of 614

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Reason For

Change

BRINE TO WATER HEAT PUMP05-33 05-33 BRINE TO WATER HEAT PUMP





requirements.

6M 1. Status. Isolate electrically. Note: Isolation of electrical



(www.hse.gov.uk) requirements.

6MOther

Page 55 of 614

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Reason For

Change

05-34 PACKAGED STEAM GENERATORS

The yearly tasks shown below are generally carried out at the same time as the annual statutory

(insurance)inspection.


WORK, close off the area. Take actions in accordance with the asbestos regulations.


Added


Self-monitoring

controls

Added

1. Water gauge

test




action taken.

1DAdded

2. Water level left

hand gauge

Manually blow down. Record time test carried out.1DAdded

3. Water level right

hand gauge

Manually blow down. Record time test carried out.1DAdded

4. Water level

control

Test low water level cut-out and

lock-out.





1DAdded

5. Feed pump

start/stop or

modulation

Check operation. Record time test carried out.1DAdded

6. Pressure

reading

Record pressure gauge reading. Record time test carried out.1DAdded

7. Feed water and

condensate check

Check the feed tank level is

adequate and there are no

contaminants.

Check that the chemical dose

metering device is functioning and

there are adequate chemical stocks

in the tanks.

Check that the in-house routine

sample results are within their given

parameters provided by the water

treatment specialist and take

remedial action when necessary.

Check the temperature is above the

required level for the treatment

doses specified for oxygen

scavenging.




action taken.

1DAdded

8. TDS water test Carry out TDS (total dissolved

solids) water quality test, record the

result and make adjustments where

necessary.


Page 56 of 614

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Reason For

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9. pH water test Carry out pH water quality test,




10. Blow down Record quantity of water blown

down.


11. Flame failure Test flame failure lock-out.

This may not be present on non self

monitoring boilers

Record time test carried out.1WAdded

12. Failure to

ignite

Test failure to ignite lock out. Record time test carried out.1WAdded

13. Water level 1st Test by lowering water level to 1st




sounded.



limits.





1WAdded

14. Water level

2nd

Test by lowering water level to 2nd




sounded.



limits.





1WAdded

15. Boiler flue

ways, combustion

chamber and

connecting flue.






12MAdded

16. Fire tubes. Open boiler end doors and clean


scouring equipment.


clean all passes.

12MAdded

17. Refractory

linings.

Check condition and report.12MAdded

18. Boiler flue

ways, doors and

chamber.


necessary.

12MAdded

19. Flue. Carry out smoke test.12MAdded

20. Waterside. Remove manholes, clean out scale








disposal regulations may apply.

12MAdded

21. Boiler. Refill, reconnect and bring on line. Refit casing if necessary and


12MAdded

Page 57 of 614

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Reason For

Change

22.

Instrumentation

and flame

monitoring.

Check for operation and accuracy. Recalibrate and reset if necessary.12MAdded

23. Combustion

check.


tests.







monoxide.

12MAdded

24. Blow down

tank.


Sanitary and waste water plumbing

SFG 48-04

HSE document PM60 applies.12MAdded

Page 58 of 614

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Reason For

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05-35 PAKAGED STEAM GENERATORS - ELECTRIC


1. Status. Check and isolate by removing fuse

links.

3MAdded

2.Water drain unit. Check for free flow of water by

operating the valve. Repair any

valve gland leaks.

3MAdded

3. Boiler

circulated water.

Test for correct conductivity. This is to be within the boiler makers

recommendation.

3MAdded

4. a) Electrical

connections.

Check all electrical connections in

the cubicle and on the boiler

electrodes for soundness and

correct any defects.

12MAdded

b) Porcelain

insulators.

Examine for defects and replace if

necessary. Clean with non-abrasive

material.

12MAdded

5. Drain pipe. Check for free flow, actuate main

drain if necessary.

12MAdded

6. Feed solenoid

(if fitted).


strainer.


driven by an electric motor. (See

also Motors SFG 39)

12MAdded

7. Load control

system.

Examine mechanism and lubricate. Comply with manufacturers

recommendation for lubrication of

the gear box, motor and control

shaft and nut.

12MAdded

8. Boiler

sequence.

Replace all covers and reinstate

electrical supply.

Ensure all electrical and mechanical

covers are in their correct places.

12MAdded

Page 59 of 614

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05-36 STEAM BOILER REPORT - PERIODIC EXAMINATION

This task is generally carried out and incorporates the yearly maintenance schedule refer to Boilers -

Heat generators SFG 05-20

A written scheme of examination [WSE] for all steam boilers is a legal requirement under regulation 8

of the Pressure Systems Safety Regulations (PSSR) 2000.

The WSE sets out the nature and frequency of examination and should adequately describe the

system, including all the pipework, vessels, safety devices and any other parts that could give rise to

danger. It will also specify any special measures necessary to prepare the system for the examination.

The scheme must be certified by a competent person and be available on site at all times. The client /

owner of the system is responsible for ensuring that a scheme has been drawn up and that the

competent person who certifies it has sufficient relevant knowledge and experience to carry out this

task.

The periodic examination as identified by the WSE for a steam boiler should include an

out-of-service examination (cold, offline, open for inspection) followed by an in-service examination at

normal operating pressure to check that all protective and control devices are working properly.

The competent person does not need to be the same one who compiled the written scheme of

examination, so the current or a controlled copy of the scheme should always be available on site.

The client / owner of the system is responsible for arranging for the competent person to carry out the

examination in accordance with the written scheme of examination.

Records

The following documentation and records need to be retained:

- The report of the last examination under the written scheme of

examination;

- Any details of repairs or modifications to the system (including changes to the operating

parameters);

- Any previous reports containing information relating to the safe

operation of the system;

- Routine testing records for the previous two years; and

- Technical documentation supplied by the manufacturer and installer of the boiler and associated

equipment.

These documents must be available to the boiler operator, the

competent person and any new user or owner of the pressure equipment.

Added

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05-37 BOILER SUPERHEATER

The yearly tasks shown below are generally carried out at the same time as the Annual Statutory

(Insurance) Inspection.




Added


1. Internal and

external areas

Carry out an internal and external

examination of the heater.

12MAdded

2. Headers Inspect all weld sections for any

signs of cracking. Check for

deposits that have accumulated in

the header, clean out as required.

Thermal cracking at the headers

due to high stresses set up across

the thick welded section is possible.

12MAdded

3. Safety valve

and stop valve

Check for leakage, corrosion and

manually operate.

12MAdded

4. Drain and vent

valves

Inspect and repair as necessary12MAdded

5. Manhole

openings

Check all contact surfaces for

pitting. Clean any scale/deposits.

12MAdded

6. Screen plates Check condition and clean as

necessary.

12MAdded

7. Tubes Check for signs of thermal fatigue

and scale. In the case of scale

being present this should be

cleaned off. It is important to clean

all passes.

Oxide scaling inside or outside may

cause tube failure and at the worst

case a hydrogen fire which is when

iron burns in steam at above 700°C

in an exothermic reaction.

Sodium and vanadium compounds

present in the deposits proved very

corrosive to superheater tube

causing frequent repeated failure.

12MAdded

8. Walk-in spaces Check the supports of the

horizontal super heater tubes for

signs of thermal damage and

potential failure. Clean all deposits

from the spaces. Check the

condition of the tubes special

attention to be paid to tubes

through which there still exists gas

paths as they operate under

excessive metal temperature.

A build-up of deposits is most

troublesome defect in a super

heater. These may result in high

furnace pressure, loss of super

heater and poor combustion.

12MAdded

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05-38 BIOMASS BOILER

The burning of biofuels is a complex operation involving the storage, handling and combustion of solid

material, plus the handling, disposal of gaseous and solid waste. The materials can be abrasive with

the wear and tear on mechanical plant considerable, hence regular maintenance is vital to ensure

continuous working and a clean environment. The maintenance of each section of the biomass boiler

is examined in sequence.

Maintenance levels of all biomass boilers will vary according to the type of system and fuel being burnt

for instance a pellet system strongley differs from a woodchip system in terms of frequency .

Added


1. Weekly check Inspect boiler and fuel feed system.

Listen for noisy fan operation.

Check flue gas temperature and the

colour out of the stack. Record in

log. Check boiler temperature and

record in log. Function test

back-burn devices and negative

pressure indicators. Check

pressure switches. Check

emergency stops for both bunker

and auger operate.

1WAdded

2. Hydraulic

aggregate [if fitted]

Check oil level and top up as

required. Check that the pressure

and operational temperature are as

per the manufacturers guidelines.

Check for any oil leaks from the

seals and hoses.

1MAdded

3. Operational

status.



fuses, if used.





of the permit.

3MAdded

4. Multicyclone Clean the mulitcyclone using an

industrial vacuum cleaner.

3MAdded

5. Rost Remove ash from the rost3MAdded

6. Combustion

Chamber

Clean retort, fire bricks, combustion

surface and combustion chamber

3MAdded

7. Burning Grate Remove ash from the combustion

space and clean grate. Ensure all

ash from beneath the step grate is

removed.

3MAdded

8. Heat exchanger Clean the tubes in the heat

exchanger with the appropriate

brush

3MAdded

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9. Fans Clean suction blower from ash

using an industrial vacuum cleaner.

Check low level switches, fuses and

action of fan emergency safety

switch in OFF position.

Pay attention to the flue gas sensor

when cleaning the flue gas pipe.

3MAdded

10. Flue and

chimney

Clean3MAdded

11. Auger Lubricate the worm bearings.

Inspect for wear.

Use only lubricants as detailed by

the manufacturers guidelines.

3MAdded

12. Ash conveying

system [if fitted]

Lubricate the all bearings. Use only lubricants as detailed by

the manufacturers guidelines.

3MAdded

13.Pneumatic

system. (Applies

to both feed and

ash removal,

where fitted).



tightness.



timing sequence, (d) check `bags`,


as appropriate . It is essential to

maintain air tightness on pneumatic

systems otherwise the coal feed

cannot be maintained, output is

reduced and energy wasted.

3MAdded

14. Ash container Clean out ash content in the

container, empty it when necessary.

This frequency will depend on the

type of system and the hours

system used.

Added

15. Igniters Clean igniter and igniter tube.6MAdded

16. Compressor [if

fitted]

See SFG 40-08 for full compressor

tasks

6MAdded

17. Motors Clean motors see Motors SFG

39-01

6MAdded

18. Boiler room

ventilation



Boiler room ventilation should

comply with BS 5440 -2: 2009 for

boilers not exceeding 70kW and BS

6644:2005 for boilers with a

capacity between 70kW and 1.8MW

12MAdded

19. Electrical. Check all electrical trips. These should be set for manual

reset.

12MAdded

20. Silo discharge Grease gears24MAdded

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05-39 GAS BOOSTER SETS

Before carrying out any maintenance on the Booster, all Electrics and gas pressure should be turned

off.

Maintenance should be carried out in full accordance with the manufacturers instructions and using

only replacement parts supplied or authorised by the manufacturer.

Added


1) General Check for leaks and general

condition. Check for excessive

noise or vibration and ensure that

the mountings are secure and in

good condition.

3MAdded

2). Air fan inlets Check that the air fan inlets are not

obstructed by

dust or dirt and clean out if

necessary

3MAdded

3). Glands and

seals

Ensure that all glands and seals on

gas boosters are sound and that

there is no smell of gas in the area.

3MAdded

4). Warning

notices

Ensure that warning notices are

correctly displayed.

3MAdded

5) Motors The bearings generally are sealed

for life and usually left in service

until their replacement is required.

12MAdded

6) Drive belts Replace drive belts using

manufacturers replacement belts.

If the drive has more than one belt

ensure all belts are changed at the

same time.

Do not apply belt dressing.

1) Isolate the electricity supply.

2) Remove the belt guard.

3) Remove the existing belt.

4) Clean the pulley running

surfaces.

5) Lift the motor platform and

position a new belt on both pulleys.

The smooth side of the belt should

be in contact with the pulley

surfaces.

6) Ensure the belt will run centrally

on the pulley faces.

7) Replace the belt guard.

12MAdded

7) Booster bearing

assemblies

Replace bearing assemblies

irrespective of perceived bearing

condition.

A rise in noise level or vibration

indicates that the bearings are in

need of replacement. With the belt

guard removed a further check can

be made for radial or axial

movement of the shaft within the

bearing housing.

60MAdded

8) Flexible

connectors

Replace flexible connectors.60MAdded

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05-40 GAS GOVERNOR OR GAS REGULATOR


1) Diaphragms Individual appliance governors

should be examined to ensure that

diaphragms are sound and in good

condition.

12MAdded

2). Valves and

seatings

Valves and seatings should be

cleaned and any rust or dust

deposits removed.

12MAdded

3). Impulse pipes Check that impulse pipes are clear,

sound and secure.

12MAdded

4). Outlet pressure Check that the outlet pressure

should be reasonably constant

between low and high fire rates.

12MAdded

Page 65 of 614

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05-41 GAS INCINERATOR

A risk assessment and method statement must be undertaken in accordance with the confined spaces

regulations, before entering any confined space such as a hopper, flue chamber or boiler to ensure

that there is adequate ventilation and an absence of any fumes or flue gases


WORK, close off the area. Have sample Certified as safe before any works can re-start, if asbestos,

take actions in accordance with the asbestos regulations.


Added


1. Outer case /

panels.

Remove as required If a leak is detected, shutdown the

gas source, reduce pressure to

atmospheric, and tighten or redo the

leaking connection. Retest.

12MAdded

2. Grate / Ash pan Riddle the grate, check for freedom

of movement, clear primary

chamber of ash. Remove and

empty ash draw or pan.

12MAdded

3. Pilot burner Remove and clean pilot burner.12MAdded

4. Primary and

secondary burners

Remove and clean primary and

secondary burners.

Check that injectors are clear,

burner tunnel clear and ports are

free from blockage.

12MAdded

5. Refractory

lining, combustion

chambers and flue

ways.

Examine condition of refractory

lining to primary chamber. Clear

any dust from secondary chamber

and check that the flue ways are

clear.

Report any problems to the client.12MAdded

6. Door

mechanism

Clean and check door mechanism.12MAdded

7. Linkages and

interlocks

Clean linkages and interlocks and

adjust if necessary.

12MAdded

8. Gas control

cocks

Check gas control cocks, ease and

grease if required

12MAdded

9. Gas burners Rebuild and install in reverse as

sequence dictates.

12MAdded

10. Gas system Check gas soundness.12MAdded

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11. Ignition Light the appliance and check any

ignition device.

Check pilot stable and correctly

positioned.

Check burner pressures or gas rate

at the meter if necessary.

12MAdded

12. Flue Check flue for pull and spillage12MAdded

13. Controls Check controls

– flame protection device

– timer set correctly

– any other control devices

12MAdded

14. Sequence

timer

Check that the timer returns to

zero, shutting down the appliance

at the end of the combustion cycle.

Added

Page 67 of 614

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05-42 WASTE INCINERATOR

A risk assessment and method statement must be undertaken in accordance with the confined spaces

regulations, before entering any confined space such as a hopper, flue chamber or boiler to ensure

that there is adequate ventilation and an absence of any fumes or flue gases


WORK, close off the area. Have sample Certified as safe before any works can re-start, if asbestos,

take actions in accordance with the asbestos regulations.


Added


1. Ash removal

conveyor

Inspect and clean as required.1HAdded

2. Water quench

pit

Inspect water level and fill as

required.

1HAdded

3. Opacity monitor Check operation of the opacity

monitor and check exhaust for

visible emissions.


4. Oxygen monitor Check operation. Record time test carried out.1DAdded

5. Thermocouples Check operation. Record time test carried out.1DAdded

6. Underfire air

ports

Inspect and clean as required.1DAdded

7. Limit switches Inspect for freedom of operation

and potential obstructing debris.

1DAdded

8. Door seals Inspect for wear, closeness of fit,

and air leakage.

1DAdded

9. Ash pit/internal

dropout sump

Clean after each shift. This applies to units that do not

have a continuous ash conveyor

cleaning system.

1DAdded

10. Heat recovery

boiler tubes

Inspect and clean as required.1WAdded

11. Blower intakes Inspect for accumulations of lint,

debris. Clean as required.

1WAdded

12. Burner flame

rods (gas fired

units)


13. U.V. Scanner

flame sensors


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14. Swing latches

and hinges

Lubricate.1WAdded

15. Hopper door

support pins

Lubricate.1WAdded

16. Ram feeder

carriage wheels

Lubricate.1WAdded

17. Heat recovery

induced-draft fans

Inspect and clean fan housing as

required.

Check for corrosion and V-belt

drives and chains for tension and

wear.

1WAdded

18. Hydraulic

systems

Check hydraulic fluid level and add

the proper replacement fluid as

required. Investigate sources of

fluid leakage as required.

2WAdded

19. Ash removal

conveyor bearings

Lubricate.2WAdded

20. fuel trains and

burners


21. Control panels Inspect and clean as required. Keep panel securely closed and free

of dirt .

2WAdded

22. External

surface of

incinerator and

stack

Inspect external "hot" surfaces. White spots or discolouration may

indicate loss of refractory.

1MAdded

23. Refractory Inspect and repair minor wear

areas.

1MAdded

24. Internal ram

faces

Inspect for wear. Stainless steel faces may wear out

and require replacement in 1 to 5

years depending on service.

1MAdded

25.

Upper/secondary

combustion

chamber

Inspect and vacuum and particulate

matter that has accumulated on the

chamber floor.

1MAdded

26. Combustion air

blowers and heat

recovery induced

draft fans

Lubricate. Some of these bearings are sealed

for life so do not need lubricating.

1MAdded

27. Hydraulic

cylinder clevis and

trunnion

attachments to all

moving

components

Lubricate.1MAdded

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28. Burner pilots Inspect and adjust as required.1MAdded

29. Hot external

surfaces

Inspect for signs of damage.6MAdded

30. Chains Inspect and brush clean as

required. Lubricate.

6MAdded

31. Outer case /

panels.

Remove as required If a leak is detected, shutdown the

gas source, reduce pressure to

atmospheric, and tighten or redo the

leaking connection. Retest.

12MAdded

32. Grate / Ash

pan

riddle the grate, check for freedom

of movement, primary chamber

clear of ash. Remove and empty

ash drawer or pan.

12MAdded

33. Pilot burner Remove and clean pilot burner.12MAdded

34. Primary and

secondary burners

Remove and clean primary and

secondary burners. check that

injectors are clear, burner tunnel

clear and ports free from

blockage.

12MAdded

35. Refractory

lining, combustion

chambers and flue

ways.

Examine condition of refractory

lining to primary chamber. Clear

any dust from secondary chamber

and check that the flue ways are

clear.


36. Door

mechanism

Clean and check door mechanism.12MAdded

37. Linkages and

interlocks

Clean linkages and interlocks and

adjust if necessary.

12MAdded

38. Gas control

cocks

Check gas control cocks, ease and

grease if required

12MAdded

39. Gas burners Replace as sequence dictates.12MAdded

40. Gas system Check gas soundness.12MAdded

41. Ignition Light the appliance and check any

ignition device.

Check pilot stable and correctly

positioned.

Check burner pressures or gas rate

at the meter if necessary.

12MAdded

Page 70 of 614

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42. Flue Check flue for pull and spillage12MAdded

43. Controls check controls

– flame protection device

– timer set correctly

– any other control devices

12MAdded

44. Sequence

timer

Check that the timer returns to



12MAdded

Page 71 of 614

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05-43 WET SCRUBBER SYSTEM

Legionellosis (Legionnaires Disease and Associated Illnesses)

Approved Code of Practice- Legionnaires disease: The control of legionella bacteria in water systems:

Approved Code of Practice, L8,2000 sets out certain statutory requirements. In particular each water

system must be identified and assessed for legionellosis risk. Once a risk has been identified and

assessed a scheme must be prepared for preventing or controlling it, precautions implemented and

managed records kept. The L8 has a special legal status, Part 1 being regulatory and Part 2

guidance.

The client must ensure that one person of adequate status is appointed as being responsible for

overseeing the assessment and implementation of the precautions. Responsibility and lines of

communication must be properly defined and personnel must be properly trained.

Added


1. Scrubber liquid

pump

Check for proper operation and

leakage. Investigate sources of fluid

leakage and repair as required.

1DAdded

2. Variable throat

activator


leakage.

1DAdded

3. Scrubber liquid

lines

Check for leakage. Repair as

required.

1DAdded

4. Mist eliminator

pressure lines


required.

1DAdded

5. Reagent feed

system


required.

1DAdded

6. Fan, Fan

bearings and fan

belt

Check for vibration and proper

operation. Check for abnormal

noise.

1DAdded

7. Fan Check oil level, oil colour, oil

temperature and lubricate.

1WAdded

8. Scrubber liquid

pump

Check oil level and lubricate pump

motor bearings.

1WAdded

9. Damper air

purge system

Check for proper operation.1WAdded

10. Ductwork Check for leakage. Repair as

required.

1MAdded

11. Fan and motor

bearings

Inspect for leaks, cracks and loose

fittings.

1MAdded

12. Fan blades

and internal

housing

Inspect for material build-up and

clean as required. Inspect for

abrasion and corrosion and repair

as required.

1MAdded

Page 72 of 614

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13. Drain chain

drive mechanism

Check chain tension, sprocket wear

and alignment and oil level.

1MAdded

14. Pipes and

manifolds

Inspect for plugging/leaking and

clean/repair as required.

1MAdded

15. Dampers Check for leakage.1MAdded

16. Spray bars Inspect for nozzle wear and

plugging and clean as required.

1MAdded

17. Pressure

gauges

Check for accuracy.1MAdded

18. Main body of

scrubber

Inspect for material build-up and

clean as required. Inspect for

abrasion and corrosion and repair

as required.

1MAdded

19. Fan, pump,

motor and drag

chain bearings

and gear reducers

Inspect clearances and wear, pitting

and scoring. Inspect for leaks,

cracks and loose fittings.

6MAdded

20. Flow meters Check for accuracy.6MAdded

21. Damper drive

mechanism


alignment.

6MAdded

22. Damper seals,

bearings, blades

and blowers

Check for wear and leakage.6MAdded

Page 73 of 614

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05-44 FABRIC FILTER SYSTEM


1. Stack Check exhaust for visible dust.1DAdded

2. Manometer Check and record fabric pressure

loss and fan static pressure.

Watch and record trends.1DAdded

3. Compressed air

system

Check for air leakage (low

pressure). Check valves.

1DAdded

4. Collector Observe all indicators on control

panel and listen to system for

properly operating subsystems.

1DAdded

5. Damper valves Check all isolation, bypass and

cleaning damper valves for

synchronisation and proper

operation.

1DAdded

6. Rotating

equipment and

drives

Check for signs of jamming,

leakage, broken parts and wear etc.

1DAdded

7. Dust removal

system

Check to ensure that dust is being

removed from the system.

1DAdded

8. Filter bags Check for tears, holes, abrasion,

proper fastening, bag tension, dust

accumulation on surface or creases

and folds.

1WAdded

9. Cleaning

system

Check cleaning sequence and cycle

times for proper valve and timer

operations.

Check compressed air lines

including oilers and filters. Inspect

shaker mechanisms for correct

operation.

1WAdded

10. Hoppers Check for bridging or plugging.

Inspect screw conveyor for correct

operation and lubrication.

1WAdded

11. Shaker

mechanism

Inspect for loose bolts, tighten as

required.

1MAdded

12. Fan(s) Check for corrosion and material

build-up and check V-belt drives

and chains for tension and wear.

1MAdded

13. Monitor(s) Check accuracy of all indicating

equipment.

1MAdded

14. Inlet plenum Check baffle plate for wear, if

applicable wear is evident, replace.

Check for dust deposits and clean

as required.

3MAdded

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15. Access doors Check all gaskets.3MAdded

16. Shaker

mechanism

Tube type:

(tube hooks suspended from a

tubular assembly) Inspect nylon

bushings in shaker bars and clevis

(hanger) assembly for wear.

Channel shakers:

(tube hooks suspended from

channel bar assembly) Inspect drill

bushings in tile bars and connecting

rods for wear.

3MAdded

17. Motors, fans Lubricate all electrical motors,

speed reducers, exhaust and

reverse-air fans and similar

equipment.

6MAdded

18. Collector Check all bolts and welds. Inspect

entire collector thoroughly, clean as

required.

12MAdded

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05-45 SANITARY INCINERATOR

Always ensure that the main external electricity supply is switched off before attending to servicing of

the unit.

Added


1. Ash draw Empty the ash draw The ash drawer must not be allowed

to overfill. If the incinerator is in

constant use it should be emptied

weekly or more often if

it should appear necessary.

1WAdded

2. Ventilation The incinerator should have a

13mm gap between it and the wall

to which it is fixed for ventilation

purposes. Check that the gap is

clean and unobstructed.

1WAdded

3. Wiring Check the supply wiring fuse is of

the correct rating. Check for

soundness and ensure terminal

connections are secure. Check

integrity of electrical insulation.

Some units are fitted with sheathed

wire elements and it is a feature of

such an element that small amounts

of water can be absorbed from the

atmosphere if the unit is not in

regular use. It is possible that this

will decrease the earth leakage

resistance which can cause the

earth leakage cut-out to trip.

12MAdded

4. Test operation Insert the towel by fully opening the

door flap at the top of the unit. This

operation is all that is required and

automatically starts

the burning cycle. Do not fill above

the lower level of the door opening.

12MAdded

5. Time switch Check that the timer returns to



The time switch should cut out 20

minutes after the door is closed but

the charge will continue to burn.

12MAdded

6. Flue Check flue for pull. Clean flue and

ensure that the flue cleaning trap

gasket is sealed when put back in

operation. Mark positions and clean

any branch run dampers and return

to set positions. Ensure that the

cone cap is in place on the flue

system. Check and clean any

in-line fan units. Check operation

hours of the building and ensure

that any time switch controlling the

fan is running continuously during

these hours plus a run on time of

one to two hours.

12MAdded

Page 76 of 614

BUILDING MANAGEMENT SYSTEMS

Page 77 of 614

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Development

Building Management Systems (BMS) or Building Energy Management Systems (BEMS) have

developed from the simple applications of the 1970s to complex integrated systems involving

outstations and central units whose operation relies on computer interactive management backed by

detailed and often complex software which provides total management of the environmental

conditions in a building. It is an ever changing field and systems currently in operation can include

lighting, security, lifts, fire alarms, access and other interfaces.

Monitoring operation

The basic components of a BMS include sensors, actuators, controllers, communication systems and

a central unit which can be either passive, i.e. monitor and rely upon the outstations to act as local

control centres, or active and provide a central control function.

Where Building Management Systems are installed it is essential that the Client should be aware of

the need for continuous monitoring of performance. Switching off because of a malfunction or lack of

data update represents a negation of the investment and can give rise to poor environmental

conditions and energy wastage.

Energy saving and maintenance

Building Energy Maintenance Systems offer considerable energy and cost savings when compared

with more simple equipment but represent a considerable investment by the building owner or lessee .

If the equipment is not properly commissioned and maintained by specialist trained personnel

who have had training on such equipment and are supported by the manufacturer, the benefits

of such investment could be lost, energy will be wasted and costs rise.

Building owner or lessee

Building owners or lessees should ensure that their operators have had the appropriate training to

ensure that routine but important daily and weekly maintenance tasks are carried out satisfactorily.

Such tasks could include monitoring and changing time schedules, set points, environmental control

settings and simple routine maintenance of the computer hardware. Where changes are made to the

software routines it is essential that back up copies are made to safeguard the changes.

Software

The owner or lessee should be aware that software is normally covered by copyright and the licence

conditions covering its use can be very restrictive. The penalties for infringing that copyright can be

considerable. The licence may relate to the use of the software or may be restrictive and apply only to

a particular application or building If there is any doubt regarding the above, the manufacturer

should be contacted for advice.

Maintenance contractor

For the regular maintenance of the equipment the client should be satisfied that the maintenance

contractor employs BMS specialists who:-

a) have had the necessary training,

b) have knowledge of the installed system,

c) maintain an up to-date awareness of the manufacturers equipment including computer hardware

and software,

d) have access to up to-date diagnostic equipment,

e) have good technical support,

f) are supported by adequate stocks of spares.

Development

Building Management Systems (BMS) or Building Energy Management Systems (BEMS) have

developed from the simple applications of the 1970s to complex integrated systems involving

outstations and central units whose operation relies on computer interactive management backed by

detailed and often complex software which provides total management of the environmental

conditions in a building. It is an ever changing field and systems currently in operation can include

lighting, security, lifts, fire alarms, access and other interfaces.

Monitoring operation

The basic components of a BMS include sensors, actuators, controllers, communication systems and

a central unit which can be either passive, i.e. monitor and rely upon the outstations to act as local

control centres, or active and provide a central control function.

Where Building Management Systems are installed it is essential that the client should be aware of

the need for continuous monitoring of performance. Switching off because of a malfunction or lack of

data update represents a negation of the investment and can give rise to poor environmental

conditions and energy wastage.

Energy saving and maintenance

Building Energy Maintenance Systems offer considerable energy and cost savings when compared

with more simple equipment but represent a considerable investment by the building owner or lessee.

If the equipment is not properly commissioned and maintained by specialist trained personnel who

have had training on such equipment and are supported by the manufacturer, the benefits of such

investment could be lost, energy will be wasted and costs rise.

Building owner or lessee

Building owners or lessees should ensure that their operators have had the appropriate training to

ensure that routine but important daily and weekly maintenance tasks are carried out satisfactorily.

Such tasks could include monitoring and changing time schedules, set points, environmental control

settings and simple routine maintenance of the computer hardware. Where changes are made to the

software routines it is essential that back up copies are made to safeguard the changes.

Software

The owner or lessee should be aware that software is normally covered by copyright and the licence

conditions covering its use can be very restrictive. The penalties for infringing that copyright can be

considerable. The licence may relate to the use of the software or may be restrictive and apply only to

a particular application or building If there is any doubt regarding the above, the manufacturer should

be contacted for advice.

Maintenance provider

For the regular maintenance of the equipment the client should be satisfied that the maintenance

provider employs BMS specialists who:-

a) have had the necessary training,

b) have knowledge of the installed system,

Technical

Page 78 of 614

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c) maintain an up to-date awareness of the manufacturers equipment including computer hardware

and software,

d) have access to up to-date diagnostic equipment,

e) have good technical support,

f) are supported by adequate stocks of spares.

The tasks and frequencies given in the following schedules represent good practice and are typically

applied for sites with five or seven-day operation with plant and controls less than 10 years old. The

frequencies suggested may be varied to meet on-site conditions

(extremes of dust or heat), age of plant and controls, acceptance of risk of failure.

Sites with critical areas such as computer suites or operating theatres may require increased

frequency of maintenance of selected elements. Sites where risk of failure of services is acceptable

may be more selective about the maintenance frequency of certain elements. However, care should

be taken to ensure that energy savings continue to be achieved.

Page 79 of 614

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BUILDING MANAGEMENT SYSTEMS - Central Operator Station06-03 06-03 BUILDING MANAGEMENT SYSTEMS - Central Operator Station


5. Clock and

Calendar

Check real-time clock and date

settings

6MAdded

4. Tape drives. Clean according to the

manufacturer's instructions.

12M Deleted

5. Tape cassettes

(where

appropriate).

Clean according to the


12M Deleted

6. Clock battery. Check and replace if necessary. Battery disposal should be in

accordance with www.hse.gov.uk

and Environmental Requirements.

12M 4. Clock battery. Check and replace if necessary. Battery disposal should be in

accordance with www.hse.gov.uk

and Environmental Requirements.

12MOther

7. Cooling fans. Check condition, clean and

lubricate if necessary.

6M 6. Cooling fans. Check condition, clean and


Do not lubricate if sealed for life

bearings. Wipe off any excess

lubricant as it will attract dust which

will stick to it.

6MTechnical

8. Filters. Inspect and clean or change as

necessary.

6M 7. Filters. Inspect and clean or change as

necessary.

6MOther

9. Mouse. Check for smooth operation and

clean ball as necessary.

Client may ask for more frequent

maintenance of mouse.

12M 8. Mouse. Check for smooth operation and

clean ball as necessary.

client may ask for more frequent

maintenance of mouse.

12MOther

10. Software

archives.

a)Take back up copy of site specific

data files. b)Verify operating

programmes and functionality.

Ensure that security is retained and

that any updating of files is

incorporated.

6M 9. Software

archives.

a)Take back up copy of site specific

data files. b)Verify operating

programmes and functionality.

Ensure that security is retained and

that any updating of files is

incorporated. It is recommended

that a copy of the back-up data is

stored in a fire proof safe or off-site.

6MOther

11. Visual Display

Unit (VDU).

Check a)focus, b)contrast,

c)brightness, d)for correct

operation.

12M 10. Visual

Display Unit

(VDU).

Check a)focus, b)contrast,


operation.

12MOther

12. Monitor(s). Check a)focus, b)contrast,


operation, e)degauss.

With most VDUs the screen is

automatically degaussed when

equipment is switched on.

12M 11. Monitor(s). Check a)focus, b)contrast,


operation, e)degauss.

With most VDUs the screen is

automatically degaussed when

equipment is switched on.

12MOther

13. Keyboard. Check for correct operation and

clean.

12M 12. Keyboard. Check for correct operation and

clean.

12MOther

14. Cleaning. Clean with approved cleanser. Treat with anti-static compound.

Depending on use and location

more frequent cleaning may be

necessary.

12M 13. Cleaning. Clean with approved cleanser. Treat with anti-static compound.

Depending on use and location

more frequent cleaning may be

necessary.

12MOther

3. Test sequence. Check, adjust and replace if

necessary:- a)paper feed,

b)transport system, c)printer ribbon.

12M 3. Test sequence. Check, adjust and replace if

necessary:- a)paper feed,

b)transport system, c)printer

cartridge

12MTechnical

Visual Display Unit

-colourgraphic

Deleted

1. Cables and

connectors.

Check security, integrity, and for

physical damage.

12M Deleted

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2. Cleaning. Use recommended cleaning agent.12M Deleted

3. Colour

alignments and

adjustments.

Check and correct as necessary.12M Deleted

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BUILDING MANAGEMENT SYSTEMS - COMMUNICATIONS06-04 06-04 BUILDING MANAGEMENT SYSTEMS - COMMUNICATIONS


5.Alarms -

receiving

Confirm that all critical alarms are

received by the central supervisor.

Check spurious alarms and

reported faults (as incurred).

12MAdded

6. Alarms -

generating

Check generation of alarms from all

input and output devices

12MAdded

7. Network Check communications between

central supervisory computer and

outstations and other networked

devices

12MAdded

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BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS06-05 06-05 BUILDING MAINTENANCE SYSTEMS - OUTSTATIONS


5. Stand-by

batteries/

uninterrupted

power supplies

(UPS).

Interrupt electrical supply to each

outstation, reinstate and ensure

system restarts satisfactorily

12MAdded

1. Out station

hardware.

Check mechanical and

environmental condition.

Note: environmental conditions, e.g.

temperature, humidity should be

within manufacturer's recommended

limits.

12M 1. Out station

hardware.

Check mechanical and

environmental condition.

Environmental conditions, e.g.

temperature, humidity should be

within manufacturer`s

recommended limits.

12MOther

4. Stand-by

batteries/

uninterrupted

power supplies

(UPS).

Check against manufacturer's

specification.

12M 4. Stand-by

batteries/

uninterrupted

power supplies

(UPS).

Check against manufacturer`s

specification. Replace as necessary

12MTechnical

5. Digital inputs. Check by activating (where from

fixed sensing/control device)

Note: Care should be taken to

isolate local operation.

12M 6. Digital inputs. Check by activating (where from

fixed sensing/control device)

Care should be taken to isolate local

operation.

12MOther

6. Digital outputs. Check operation of output stopping

by operating routine (where

appropriate). Check switching by

software interlocks.

Should include starting and stopping

operations. Note: Does not apply to

connected devices.

12M 7. Digital outputs. Check operation of output stopping

by operating routine (where

appropriate). Check switching by

software interlocks.

Should include starting and stopping

operations. Does not apply to

connected devices.

12MOther

7. Analogue

inputs.

Read and check calibration of

analogue inputs.

12M 8. Analogue

inputs.

Read and check calibration of

analogue inputs.

12MOther

8. Analogue

outputs.

Check for accuracy of output

signal.

12M 9. Analogue

outputs.

Check for accuracy of output signal.12MOther

9. Manual

override (physical).

Check status. Review and report to client.12M 10. Manual

override (physical).

Check status. Review and report to client.12MOther

10. Installed

programme.

Check integrity, alarms, interlocks,

optimisation.

See section on SOFTWARE

FUNCTIONS.

12M 11. Installed

programme.

Check integrity, alarms, interlocks,

optimisation.

See section on Software functions

SFG 06-06

12MOther

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BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS06-06 06-06 BUILDING MANAGEMENT SYSTEMS - SOFTWARE FUNCTIONS


1. Control loops. Check integrity of the installed

programme, Check sequence,

operation of control, outputs and

check stability of plant.

Frequency should be agreed with

client. This action should be related

to the critical nature of the

operation.

12M 1. Control loops. Check integrity of the installed

programme, Check sequence,

operation of control, outputs and

check stability of plant. Undertake

as necessary fine tuning of control

loops. Adjust settings in conjunction

with the building manager to

achieve the required internal

environmental conditions

Frequency should be agreed with

client. This action should be related

to the critical nature of the

operation.

6MTechnical

3. Time clock Check real time clock for accuracy

throughout system.

12M 3. Time clock Check real time clock and date for

accuracy throughout system.

12MTechnical

4. Time

switching.

Review current operating

parameters according to client's

needs.

e.g. time settings and schedules.12M 4. Time

switching.

Review current operating

parameters according to clients

needs.

e.g. time settings and schedules.12MOther

5. Data logging. Review existing logs. Report to client on the need to

review existing arrangements.

12M 5. Data logging. Review need for existing data logs.

Delete/archive logs as required

Report to client on the need to

review existing arrangements.

12MOther

6. Alarms -

faults, out of limit

alarms.

Check that plant alarms and

software interlocks with safety

implications are operating correctly.

Check alarm priorities, routings and

reactions.

The checking of possible reactions

to certain critical alarms and

programmes must be carefully

co-ordinated with other trades and

building tenants. Where there are

safety implications, verify alarm

integrity. Review system of reporting

outstanding alarm conditions and

report discrepancies.

12M 6. Alarms -

faults, out of limit

alarms.

Check that plant alarms and

software interlocks with safety

implications are operating correctly.

Check alarm priorities, routings and

reactions. Check alarm priorities

are appropriate.

The checking of possible reactions

to certain critical alarms and

programmes must be carefully

co-ordinated with other trades and

building tenants. Where there are

safety implications, verify alarm

integrity. Review system of reporting

outstanding alarm conditions and

report discrepancies.

12MTechnical

7. Alarm

management and

report.

Review frequencies of generated

alarms.

Report as appropriate to client.12M 7. Alarm

management and

report.

Review frequencies of generated

alarms. Review alarm log records

for indication of untoward

conditions

Report as appropriate to client.12MTechnical

14. Outstations Back up all outstation files. Make

two copies. Store one on site and

one off site.

6MAdded

15. O&M`s Advise where control strategy

descriptions in operating and

maintenance manuals are incorrect.

Ensure, where appropriate,

additional documentation meets all

quality assurance procedures

12MAdded

16. Schematics Check schematics indicate correctly12MAdded

17. Log Books Maintain a log book of all changes

made to the system

As Necessary0MAdded

Page 84 of 614

BURNERS

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ATMOSPHERIC GAS BURNERS07-01 07-01 ATMOSPHERIC GAS BURNERS

These burners operate by mixing air and gas to provide an efficient combustion flame . This principle is

used mainly for domestic and small commercial equipment. Before commencing any work check the

installation for Asbestos, if suspected STOP WORK, close off the area. Have sample Certified as safe

before any works can re-start, if asbestos, take actions in accordance with the Asbestos Regulations.


These burners operate by mixing air and gas to provide an efficient combustion flame . This principle is

used mainly for domestic and small commercial equipment. Before commencing any work check the

installation for asbestos if suspected STOP WORK, close off the area. Take actions in accordance

with the Asbestos Regulations.

Refer to www.hse.gov.uk .

Other


6 Wiring to ignitor

and/or probe, gas

valve and boiler

thermostats.

Check.12M 6 Wiring to ignition

and/or probe, gas

valve and boiler

thermostats.

Check.12MOther

10. Safety check Ensure that no products of



situated.

The report must be signed by the






competent engineer. Depending on

the nature/urgency of the fault and

the type of premises this report may

be verbal.

12M 10. Safety check Ensure that no products of



situated.

The report must be signed by the









be verbal.

12MOther

11.

Documentation.







competent engineer . Depending on



be verbal.

12M 11.

Documentation.










be verbal.

12MOther

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BLOWN GAS BURNER07-02 07-02 BLOWN GAS BURNER

A fan assisted type in which the gas and air is pre-mixed before the fan. This is not a pressure jet type

burner. The air/fuel ration is controlled by an orifice plate and monitored by a pre- set differential

pressure switch.

A fan assisted type in which the gas and air is pre-mixed before the fan. This is not a pressure jet

type burner. The air/fuel ration is controlled by an orifice plate and monitored by a pre- set differential

pressure switch.




Technical


13.

Recommendation.

Provide written report. The report

should be signed by the service

engineer and the client/client

representative/responsible person.





out by a registered engineer

complying with Health and Safety

requirements and posses

accreditation in accordance with the

Gas Safety Regulations.

12M 13.

Recommendation.



engineer and the client/clients








requirements and posses



12MOther

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FORCED DRAUGHT GAS BURNER07-03 07-03 FORCED DRAUGHT GAS BURNER

A fan assisted nozzle mix type with fully automatic operation creating an expanding flame . A fan assisted nozzle mix type with fully automatic operation creating an expanding flame .




Technical


6. Fan and

motor.

Remove, thoroughly clean,


MOTORS6M 6. Fan and

motor.

Remove, thoroughly clean, lubricate

if necessary.

See Motors SFG 396MTechnical

15.

Recommendation.



engineer and the client/client








requirements and possess



6M 15.

Recommendation.



engineer and the client/clients








requirements and possess



6MOther

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FUEL OIL BURNERS USING 220/960 Sec OIL07-04 07-04 FUEL OIL DISTRIBUTION & PIPEWORK USING MEDIUM (220/960 Sec) OIL

There are four basic fuel systems, which can be subdivided into those used for distillate and those for

residual oils. The use of residual oils necessitates the inclusion of equipment for pre-heating the fuel

oil prior to the burner. This includes preheater coils in the storage tank, line tracing and final preheater

either before or right at the burner nozzle. The oil supply temperature at the burner inlet must be

sustained at the burner pump inlet as follows:

Class F (960 sec Redwood No 1 - 20cSt @ 100oC in SI units) 43oC-55oC, at burner nozzle 104oC

Class E (220 sec Redwood No 1 - 8cSt @ 100oC in SI units) 10oC-21oC, at burner nozzle 82oC

There are four basic fuel systems, which can be subdivided into those used for distillate and those for

residual oils. The use of residual oils necessitates the inclusion of equipment for pre-heating the fuel

oil prior to the burner. This includes preheater coils in the storage tank, line tracing and final

preheater either before or right at the burner nozzle. The oil supply temperature at the burner inlet

must be sustained at the burner pump inlet as follows:

Class F (960 sec Redwood No 1 - 20cSt @ 100 deg C in SI units) 43 deg C-55 deg C, at burner

nozzle 104 deg C

Class E (220 sec Redwood No 1 - 8cSt @ 100 deg C in SI units) 10 deg C-21 deg C, at burner

nozzle 82 deg C

Other


4. Insulation. Examine and replace or repair as

necessary.

12M 4. Insulation. Examine and replace or repair as

necessary.








12MLegislative

5. Filters. Clean and change if necessary. Sludge in heavy fuel oil can be a

major fault in a burner operation and

regular checking of filters and

cleaning of tanks may be necessary

if oil is only used intermittently. To

dispose of waste away from site the

operator must have a Waste

Disposal License , Risk Assessment

may be required.

12M 5. Filters. Clean and change if necessary. Sludge in medium fuel oil can be a

major fault in a burner operation and

regular checking of filters and

cleaning of tanks may be necessary

if oil is only used intermittently.

12MTechnical

Page 89 of 614

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FORCED DRAUGHT [PRESSURE JET] OIL BURNER07-05 07-05 FORCED DRAUGHT [PRESSURE JET] OIL BURNER

A fan assisted nozzle oil air mix fully automatic. A fan assisted nozzle oil air mix fully automatic.




Technical


9. Motor and fan. Remove, clean and lubricate as



coupling before re-assembling.(See

also MOTORS

3M 9. Motor and fan. Remove, clean and lubricate as



coupling before re-assembling.(See

also Motors SFG 39-01)

3MTechnical

16. General. Check security of mechanical parts

and secure mounting of appliance.

A maintenance check should be

carried out on this type of burner

twice a year but refer to

manufacturer's specification .

All service and maintenance works

must be carried out by a

competetent engineer in

accorddance with BS 5410 codes of

practice for oil firing.

3M 16. General. Check security of mechanical parts

and secure mounting of appliance.

A maintenance check should be

carried out on this type of burner

twice a year but refer to

manufacturer`s specification .

All service and maintenance works


engineer in accordance with BS

5410 (http://www.bsi-global.com)

codes of practice for oil firing.

3MOther

private All service and maintenance works


engineer in accordance with BS

Codes of Practice for oil firing.

Deleted

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LIGHT OIL VAPORISING POT BURNER07-06 07-06 LIGHT OIL VAPORISING POT BURNER

A simple oil burner. A simple oil burner.




Technical


10.

Recommendation.

Provide written report, which should


and kept by the client.

Premature failure will result if

satisfactory service is not carried

out. All service and maintenance

must be carried out by a registered

engineer in accordance with

HSAWA requirements and in

accordance with BS Code of

Practice for Oil Firing.

3M 10.

Recommendation.

Provide written report, which should


and kept by the client.

Premature failure will result if




engineer in accordance with

HSAWA (http://www.hse.gov.uk)

requirements and in accordance

with BS Code of Practice

(http://www.bsi-global.com) for Oil

Firing.

3MOther

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GAS/OIL BURNERS - Dual fuel07-07 07-07 GAS/OIL BURNERS - Dual fuel

Burners of this type should be serviced every three months, certain operations require a lesser

frequency and this is noted in the frequency column. These units are specialised and should only be

serviced by trained personnel. This does not apply to the filters which should be cleaned by the

customer at least once per week.

Burners of this type should be serviced every three months, certain operations require a lesser

frequency and this is noted in the frequency column. These units are specialised and should only be

serviced by trained personnel. This does not apply to the filters which should be cleaned by the

customer at least once per week.




Technical


3. Ignitor. Check.3M 3. Ignition. Check.3MTechnical

4. Main shaft on

burner.

'Lift' bearings.12M 4. Main shaft on

burner.

Lift` bearings.12MOther

2. Report and

Recommendations

.

Should be signed by service

engineer and kept by the client.

Premature failure may result if




engineer in accordance with current

HSAWA requirements.

12M 2. Report and

Recommendations

.

Should be signed by service

engineer and kept by the client.

Premature failure may result if




engineer in accordance with current

HSAWA (http://www.hse.gov.uk)

requirements.

12MTechnical

Page 92 of 614

CHILLERS - WATER

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Air conditioning equipment may come in discrete packages where a particular unit operation can be

identified with a single piece of equipment, conversely a number of unit operations can be combined

into a single `package'. These packages may be small as in a wall mounted air conditioner or they

may be large free standing units of 100 kW or more often placed on the roofs of buildings. Items of

plant producing mechanical cooling include package chillers, absorption type units, refrigerant

compressors, evaporators, refrigeration condensers and refrigeration distribution systems with their

associated controls. More detailed maintenance procedures for controls are to be found at relevant

sections.

Air conditioning and refrigeration equipment traditionally used ozone depleting refrigerant fluids as the

cooling medium. Care should be exercised to check the type of refrigerant currently in use in each

system, before service is carried out. European and UK legislation was introduced controlling the use

of CFC refrigerants for servicing and phased out their use in servicing by 2000. This action ensures

compliance with statute and avoids environmental damage. Refrigerants R134a, R407C and R410a

are typical of those currently in use.

These contractors must belong to a Certified Scheme provider, in accordance with the "F" Gas and

Building Regulations.

ALL REFIGERANTS MUST BE RECOVERED FOR RECYCLING OR DESTRUCTION

Refrigeration equipment may come in discrete packages where a particular unit operation can be

identified with a single piece of equipment, conversely a number of unit operations can be combined

into a single `package`. These packages may be small as a wall mounted versa temp type unit or they

may be large free standing units of 100 kW or more often placed on the roofs or in basements of

buildings. Items of plant in the cooling system include package chillers, absorption type units,

refrigerant compressors, evaporators, refrigeration condensers and refrigeration distribution systems

with their associated controls. More detailed maintenance procedures for controls and refrigeration

distribution systems are to be found in relevant SFG sections.

Commercial air conditioning and refrigeration equipment traditionally used ozone depleting

refrigerants in the refrigeration process. Care should be exercised to check the type of refrigerant

currently in use in each system, before service is carried out. European and UK legislation was

introduced controlling the use of HCFC refrigerants for servicing and phased out their use in servicing

by 2015. This action ensures compliance with statute and avoids environmental damage. Refrigerants

R134a, R407C and R410a are typical of those currently in use.

These providers must belong to a Certified Scheme provider, in accordance with the "F" Gas and

Building Regulations.

ALL REFIGERANTS MUST BE RECOVERED FOR RECYCLING OR DESTRUCTION.

ALWAYS UPDATE RECORDS.

Technical

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PACKAGED CHILLER UNITS09-02 09-02 PACKAGED CHILLER UNITS

Warning Chiller units may be operated remotely and it is essential that the equipment be isolated at

source before commencing any maintenance work. These notes should be read in conjunction with

the manufacturer's recommended maintenance procedures and in particular supplementary work may

be required in the case of larger units above 50kW. Many packaged water chillers have

microprocessor controls that can be interrogated using passwords. The password is usually at two

levels, level one for interrogation and level two for alterations. For service work access to level one is

required. These processors can be used for diagnostic purposes and coupled to pressure transducers

can also give pressure readings.

Warning Chiller units may be operated remotely and it is essential that the equipment be

isolated at source before commencing any maintenance work. These notes should be read in

conjunction with the manufacturer`s recommended maintenance procedures and in particular

supplementary work may be required in the case of larger units above 50kW. Many packaged water

chillers have microprocessor controls that can be interrogated using passwords. The password is

usually at two levels, level one for interrogation and level two for alterations. For service work access

to level one is required. These processors can be used for diagnostic purposes and coupled to

pressure transducers can also give pressure readings.

Where the installed power on the refrigeration system exceeds 25kW, a Written Scheme of

Examination may be required to comply with the Pressure Systems Safety Regulations 2000.

Personnel carrying out leak checking, gas recovery or other refrigerant handling activities such as

plant installation and maintenance must have a suitable refrigerant handling qualification. These

works are covered under EC Regulation 842/2006, Fluorinated Greenhouse Gases Regulations 2009

(FGG Regulations 2009)

ALWAYS UPDATE RECORDS

Legislative


16. Condensers Carry out Routine Maintenance For further guidance see

Condensers SFG 13-01

3MAdded

1. Status. Check operating status. Note: With computer room chilling

units always check with computer

staff before service or maintenance.

Do not only rely on the

microprocessor readouts, always

check against calibrated equipment

if in any doubt.

3M 1. Status. Check operating status. Before undertaking the work, check

with the building manager that the

system does not serve a heat

sensitive area such as a computer

room. If it does, confirm with the

building occupants that they are

aware that work is being carried out.

Do not only rely on the

microprocessor readouts, always

check against calibrated equipment

if in doubt.

3MOther

2. Refrigeration

circuits

Check circuit pressures and

superheat temperatures. Check

alarm and run lights and remote

alarm lights associated with packs.

Refrigeration circuits should be

alternated at least every three

months by means of the 'lead/leg'

selector switch. Where operating

information is displayed on central

console, check that no

discrepancies exist between display

and master gauges, if these hese do

occur report and change

transducer(s). For non electronic

systems check installed gauges

against master gauges.

3M 2. Refrigeration

circuits

Check circuit pressures and

superheat temperatures. Check

alarm and run lights and remote

alarm lights associated with packs.

Refrigeration chillers should be


months by means of the `lead/leg`





and master gauges, if these do





3MTechnical

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3. Refrigerant Check for refrigerant and all leaks. Refrigeration circuits should be


months by means of the 'lead/leg'





and master gauges, if these hese do





3M 3. Refrigerant Check for refrigerant and all leaks. Refrigeration circuits should be


months by means of the `lead/leg`





and master gauges, if these do




against master gauges. Systems

using R22 can only use reclaimed

stocks of gas for topping up

purposes only and this shall be

prohibited in the maintenance and

servicing of refrigeration and air

conditioning equipment from

01/01/2015.

Normal systems: <3 kg no leak test

required, 3 kg to 30 kg annual leak

test required, 30 kg to 300 kg half

yearly leak test required and >300

kg quarterly leak test required.

Hermetically sealed systems: <6 kg

no leak test required, 6 kg to 30 kg

annual leak test required, 30 kg to

300 kg half yearly leak test required

and >300 kg quarterly leak test

required.

Where a system has a refrigerant

charge greater than 300kg, an

automatic leak detection system

must be installed on the system to

comply with the F Gas Regulations

Do no overlook remote condensers

and pay particular attention to bolted

joints, sight glass stands and

atmospheric relief valve vent.

3MLegislative

5. Chilled water

supply

Check supply and return water

temperatures.

If closed system check for presence

of water.

3M 5. Chilled water

supply

Check supply and return water

temperatures.

abnormal temperatures can be a

sign of low refrigerant or poor heat

rejection

3MTechnical

7. Chiller water

flow rate.

Check that this is in accordance

with the manufacturer s

recommended figure.

3M 7. Chiller water

flow rate.

Check that this is in accordance

with the manufacturer`s

recommended figure.

3MOther

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Reason For

Change

8.Leakage Check all pumps and pipework for

leaks and rectify.

Do no overlook remote condensers

and pay particular attention to bolted

joints, sight glass stands and

atmospheric relief valve vent.

3M 8.Leakage Check all equipment and pipework

for oil and water leaks and rectify.

Check for leaks should be part of

the routine servicing. “Checked for

leakage” means that the Joints,

valves including stems, seals,

including seals on replaceable driers

and filters, parts of the system

subject to vibration, connections to

safety or operational devices of the

equipment or system is examined

for leakage using direct or indirect

measuring methods, focusing on

those parts of the equipment or

system most likely to leak. The

frequency of testing depends on

refrigerant charge and system type.

3MTechnical

9. Refrigerant

pipework.

Inspect and check for vibration,

chaffing security and leakage.

Vibration is usually the result of

loose or inadequate fixing of pipe

supports and can give rise to

leakage of refrigerant.

3M 9. Refrigerant

pipework.

Inspect and check for vibration,

chaffing, security and leakage.

Vibration is usually the result of




3MOther

10. Standby

circuits.

Check operation. Vibration is usually the result of




3M 10. Standby

circuits.

Check operation.3MOther

12. Digital

readouts.

Check operation. If serving computer facilities, check

that alarm is not connected to

computer shut-down system.

3M 12. Digital

readouts.


15. Insulation. Check condition and make good

any defects.

Poor or faulty insulation can lead to

ice build up, loss of efficiency and

energy wastage.

3M 15. Insulation. Check condition and make good

any defects however small.


loss of efficiency and energy

wastage.

3MTechnical

16. Electrical. Check for damage to flexible

conduits. Tighten all terminal

connections. Isolate control panel

and inspect for signs of

overheating. Check integrity of

electrical insulation.

Include pump motors.(See also

MOTORS)

12M 17. Electrical. Check for damage to flexible






Include pump motors. See Motors

SFG 39-01

12MOther

17. Safety

cut-outs.

Check all safety cut-outs including

high and low pressure safety

cut-outs and the antifreeze

thermostat cut-out for operation

and correct calibration.

Individual machines vary, cut outs

could include i. .oil differential

switches, ii. .oil, high and low

temperature, iii. .water temperature

differential switches on chillers and

evaporators.

12M 18. Safety

cut-outs.

Check all safety cut-outs including

high and low pressure safety

cut-outs and the antifreeze

thermostat cut-out for operation and

correct calibration.

Individual machines vary, cut outs

could include i. .oil differential

switches, ii. .oil, high and low

temperature, iii. .water temperature

differential switches on chillers and

evaporators.

12MOther

18. Pump

strainers.

Check condition. Check waterside pressure drop

across the heat exchanger(s) for

fouling. WORK ON REFRIGERANT

SYSTEMS MAY ONLY BE

CARRIED OUT BY A TECHNICIAN

WHO HOLDS A CERTIFICATE FOR

THE SAFE HANDLING OF

REFRIGERANT AND WHO

WORKS FOR A COMPANY

REGISTERED WITH REFCOM or

other Mandatory scheme provider.

12M 19. Pump

strainers.

Check condition. Check waterside pressure drop

across the heat exchanger(s) for

fouling.

12MTechnical

Page 97 of 614

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LITHIUM BROMIDE/WATER ABSORPTION CHILLERS09-03 09-03 LITHIUM BROMIDE/WATER ABSORPTION CHILLERS

This is a specialised field and requires highly experienced engineers to maintain this type of

equipment.

Note - the most important feature of an absorption system is the need to maintain as required by the

manufacturer, especially the specific gravity. These machines require daily recorded checks of

machine performance which are compared with the previous readings. Changes must be noted.

This is a specialised field and requires suitably competent engineers to maintain this type of

equipment.

The most important feature of an absorption system is the need to maintain as required by the

manufacturer, especially the specific gravity. These machines require daily recorded checks of

machine performance which are compared with the previous readings. Changes must be noted.

Lithium bromide/water units use water as the refrigerant. The water inside the unit will be boiling at

temperatures around 3 deg C, and condensing at temperatures only a little above ambient. To achieve

this, the units are under a high vacuum.

If the vacuum degrades, the unit will cease to function properly. Thus it is advisable to monitor the

vacuum level closely, and restore it using a vacuum pump when necessary. After any service work

that requires the unit to be opened, the vacuum, must always be restored, and the unit resealed.

A Written Scheme of Examination may be required to comply with the Pressure Systems Safety

Regulations 2000.


Technical


11. i. Absorber

loss, ii.

Decrystallisation,

(as required)

Determine as per manufacturer's

instructions. Experience is vital in

determining the significance of any

loss.

Recorded loss should not be greater

than 3b0 F. Measure and record:- i.

refrigerant temperature, ii.

temperature and specific gravity of

solution iii. temperature at the outlet

of the solution pump. Note:- Early

resolution of any crystallisation

problems is important as damage to

pumps may occur.

12M 11. i. Absorber

loss, ii.

Decrystallisation,

(as required)

Determine as per manufacturer`s

instructions. Experience is vital in

determining the significance of any

loss.

Recorded loss should not be greater

than 3b0 F. Measure and record:- i.

refrigerant temperature, ii.

temperature and specific gravity of

solution iii. temperature at the outlet

of the solution pump. Early

resolution of any crystallisation

problems is important as damage to

pumps may occur.

12MOther

14. Insulation Check condition and make good

any defects however small.


loss of efficiency, energy wastage

and the formation of condensation.

1MAdded

15. General

Inspection

Visually inspect for corrosion,

erosion and deformities.

1MAdded

16. Pressure relief

device

Any pressure relief device should

be checked if fitted.

1MAdded

Page 98 of 614

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GAS FIRED ABSORPTION CHILLER UP TO 18 KW COOLING CAPACITY09-04 09-04 GAS FIRED ABSORPTION CHILLER UP TO 18 KW COOLING CAPACITY

These units are Direct gas fired and maintenance of the gas burners should be carried out in line with

the relevant specification. They are available in cooling only or heat pump version. Care should be

taken as the refrigeration system contains Ammonia Solutions. Only tools which are capable of

handling Ammonia should be used. Refer HSE Document PM 8I – 1995 Safe management of NH3

refrigeration systems.

These units are Direct gas fired and maintenance of the gas burners should be carried out in line with

the relevant specification. They are available in cooling only or heat pump version. Care should be

taken as the refrigeration system contains Ammonia Solutions. Only tools which are capable of

handling Ammonia should be used.

There are a number of Laws and British Standards that must be observed when working on

ammonia systems.

A Written Scheme of Examination may be required to comply with the Pressure Systems Safety

Regulations 2000.


Legislative


11. Ammonia

Charge

Measure and record ammonia

charge

Refer to manufacturers instructions4MAdded

12. Oil Analysis take a sample of oil for analysis If excessive moisture is found,

appropriate action shall be taken to

correct the balance. If the oil is PAG

(or similar) great care should be

taken to ensure

that the sample itself is not

contaminated during handling

4MAdded

13. Compressors,

Condensers and

Evaporators

Undertake maintenance on

Compressors

For further guidance see

Compressors SFG 12, Condensers

SFG 13 and Evaporators SFG 19

6MAdded

1. General. Check that unit is level and on good

foundations

4M 1. General. Check that unit is level and on good

foundations. Visually inspect for

corrosion, erosion and deformities.

4MTechnical

2. Condenser

fins.

Visually check and clean when

required the condenser fins.

4M 2. Condenser

fins.

Visually check and clean when

required the condenser fins.

Comb any damaged areas of fins.4MTechnical

4. Condenser

fan.

Check that condenser fan height is

at design setting.

Adjust according to instruction

manual.

4M 4. Condenser

fan.

Check that condenser fan height is

at design setting.

Adjust according to instruction

manual. See also Fans SFG 20

4MOther

8. Drive Belt. Check or replace if necessary. For further maintenance procedures

see BELT DRIVES.

4M 8. Drive Belt. Check or replace if necessary. For further maintenance procedures

see Belts SFG 04

4MOther

Page 99 of 614

COLD ROOMS AND FOOD STORAGE

Page 100 of 614

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COLD ROOMS10-01 10-01 COLD ROOMS

It should be noted that the frequency of maintenance relates to equipment which is generally in clean

surroundings but where the environment is dirty, i.e. dust or fluff, more frequent maintenance may be

necessary. (See also MOTORS)

It should be noted that the frequency of maintenance relates to equipment which is generally in clean

surroundings but where the environment is dirty, i.e. dust or fluff, more frequent maintenance may be

necessary.

Refrigeration equipment containing 3kg or more of F gas refrigerant must be checked for leakage by

certified personnel on a regular basis. The frequency of testing depends on refrigerant charge and

system type.

Technical


1. Evaporator

coils.

Clean and check for any damage. Ensure unit thoroughly defrosted

and coils are free of ice before

putting back into service.

6M 1. Evaporator

coils.

Check for correct operation. Clean

and check for any damage.

Correct operation is indicated by

even frost formation on cooler face

and/or on distribution lines. Ensure

unit thoroughly defrosted and coils

are free of ice before putting back

into service.

6MOther

5. Pipework. Inspect and thoroughly leak test. Corrosion and chafing can occur at

duct entries and joints.

6M 5 Room Lighting Check operation and condition.6MTechnical

7. Evaporators. Check for correct operation. Correct operation is indicated by


and/or on distribution lines.

6M Deleted

8.

Interconnecting

pipework (where

visible).

Check for vibration and test for

leaks. Check insulation for damage

and replace/repair as necessary.

6M 8.

Interconnecting

pipework (where

visible).




Corrosion and chafing can occur at

duct entries and joints.

6MOther

9. Alarm system. Check for correct action. Chafing can occur at duct entries

and joints.

6M 9. Alarm system. Check for correct action.6MOther

11.Controls and

switches and

indicator lamps.

Carry out a visual check for wear

and arcing. Check operation of

relays, contactors and timers and

defrost time switch for correct

operation. Ensure indicator lamps

are working correctly.

6M 11.Controls,

switches and

indicator lamps.

Carry out a visual check for wear

and arcing. Check operation of

relays, contactors and timers and

defrost time switch for correct

operation. Ensure indicator lamps

are working correctly.

6MOther

12. Plant rooms

and housing.

Check ventilation not impaired. Leave clean and tidy.6M Deleted

13. Operating

temperatures.

Check for correctness, against

Certified unit.

6M 13. Operating

temperatures.

Check for correctness, against

calibrated unit.

6MOther

14. Door Lock Check for correct operation and

ensure handle is illuminated.

Ensure any personnel can exit the

cold room safely in an emergency

6MAdded

Page 101 of 614

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REFRIGERATED DISPLAY CABINETS10-02 10-02 REFRIGERATED DISPLAY CABINETS

Cleaning of cabinets will normally be carried out as part of the regular store maintenance schedule

and will to some extent be controlled by the type of merchandise being displayed. This schedule

relates to the main maintenance programme.

Cleaning of cabinets will normally be carried out as part of the regular store maintenance schedule

and will to some extent be controlled by the type of merchandise being displayed. This schedule

relates to the main maintenance programme.

Refrigeration equipment containing 3kg or more of F gas refrigerant must be checked for leakage by

certified personnel on a regular basis. The frequency of testing depends on refrigerant charge and

system type.

Technical


1. Evaporators. 6M 1. Evaporators. Check for correct operation. Clean


Correct operation is indicated by


and/or on distribution lines. Ensure

unit thoroughly defrosted and coils

are free of ice before putting back

into service.

6MTechnical

2. Fans Where excessive end float or

bearing wear. Report on need for

replacement.

6M 2. Fans Check for correct operation. Clean


Where excessive end float or

bearing wear. Report on need for

replacement.

6MTechnical

4. Electrical

connections.

Check all connections and wiring. Chafing can occur at case entries

and joints.

6M 4. Electrical

connections.

Check all connections and wiring.6MOther

5. Pipework. Inspect and thoroughly leak test. Corrosion and chafing can occur at

case entries and joints.

6M 5. Pipework. Check for vibration and test for





6MOther

8.

Interconnecting

pipework (where

visible).




6M 8.

Interconnecting

pipework (where

visible).






6MTechnical

9. Case

thermometer.

Check for correct reading with

Certified service thermometer.

6M 9. Case

thermometer.

Check for correct reading with

calibrated service thermometer.

6MOther

Page 102 of 614

COMMUNICATION AND P.A. SYSTEMS

Page 103 of 614

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COMMUNICATIONS - PUBLIC ADDRESS SYSTEMS11-01 11-01 COMMUNICATIONS - PUBLIC ADDRESS SYSTEMS

Ensure that, following all inspection visits, conditional reports shall be submitted to the client, including

all specialist reports and test equipment printouts.

In addition, ensure that a Site Logbook is maintained on site containing duplicate copies of all the

reports information submitted to the client.

Added


1.Microphones. Inspect and check all connection

leads, plugs and sockets, Operate

speech key and check anode

currents,

3M 1 General Clean equipment , check leads for

breaks, splits and loose

connections.

Damp wipe leads to remove

stickiness check the lead and make

repairs if necessary.

Check all amplifier connections,

knobs and sliders - tighten any that

are loose and remove excess dust

or foreign objects in those that are

sticking.

Ensure all leads are neatly coiled to

avoid twisting and tangles.

Any evidence of tampering or

damage should be recorded and

reported to the client.

12MTechnical

2.Power amplifier. Inspect and test using signal

generator.

3M 2 Audio equipment Clean the heads on audio cassette

decks, cd and minidisc players.

Leave them to dry for a few minutes

before attempting to use the player

again.

12MTechnical

3.Fire alarm

interface.

Check functioning of interface.3M 3 Speakers Check all distribution field wiring

and containment.

Check to ensure that all leads are

plugged in firmly into the correct

connectors which should also be

tightened if loose.

Ensure that sound quality is good

and free from crackling.

Inspect for damage.

Test each speaker and check

earthing where appropriate.

Check that music and other on-line

activities are cut out when

announcements are made.

12MTechnical

4.Electrical

insulation.

Measure insulation resistance of

installation cables.

12M 4 Microphones Check the base of the microphone

for bent or loose pins.

Repair if necessary.

Operate speech key and check

anode currents.

12MTechnical

5.Loud speakers. Inspect for damage. Test each

speaker and check earthing where

appropriate. Check that music and

other on-line activities are cut out

when announcements are made.

12M 5 Canon Leads Undo the screw at the side of the

canon plug, carefully remove the

centre from the casing to it`s limit

(tugging and pulling may disconnect

the wires) and check that the wires

inside are firmly soldered. Any wire

that has become detached should

be re-soldered into place.

12MTechnical

Page 104 of 614

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6. Functional test. Test system.12M Jack & Phono

Leads

Unscrew the casing and lower

gently, check that the wires are

firmly in place and re-solder if

necessary.

12MTechnical

7 Hearing

assistance

induction loop

Check loop is active and is not

suffering any `Blind Spots`.

If any found report to the client.12MAdded

8 Power supplies Check mains power supplies.

Examine all plugs and fuses for

condition.

Measure resistance of installation

cables.

12MAdded

9 System Test system is fully operational Provide a signed engineer’s report,

one copy to be left in Site Log Book

and a further copy to be submitted

to the client.

12MAdded

10. Fire Alarm

interface

Check functioning of interface.12MAdded

Page 105 of 614

COMPRESSORS - REFRIGERATION

Page 106 of 614

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COMPRESSORS REFRIGERATION - Reciprocal - (includes hermetic,

semi-hermetic and open)

12-01 12-01 COMPRESSORS REFRIGERATION - Reciprocal - (includes hermetic,

semi-hermetic and open)

These machines come in a wide range of sizes, the larger machines can be complex both in terms of

operation and maintenance requirements. In the case of compressors serving small air conditioning

systems which may only run during the summer months, these may require less frequent

maintenance.

For the maintenance of rotary compressors refer to the manfacturer's maintenance instructions.

These contractors must belong to an Approved Certified Scheme provider, in accordance with the "F"

Gas and Building Regulations.




maintenance.

For the maintenance of rotary compressors refer to the manufacturer`s maintenance instructions.


Examination may be required to comply with the Pressure Systems Safety Regulations 2000

Service providers must be registered to an Approved Certified Scheme provider , in accordance with

the F Gas and Building Regulations.

Technical


4. Leaks. Check for oil and refrigerant leaks.

Any leak of refrigerant should be

dealt with immediately.


the routine servicing by plant

attendants.

6M 4. Leaks. Check for leaks should be part of


attendants.






Technical

5. Oil in

crankcase.

Check level and condition. This should be carried out on a

monthly basis by the plant

attendant.

6M 5. Oil in

crankcase.

Check level and condition.6MOther

9. Safety

cut-outs.

Test and ensure correct operation. Include high pressure cutouts, low

pressure cutouts and oil pressure

cutouts.

6M 9. Safety

cut-outs.

Test and ensure correct operation. Include high pressure cut-outs, low

pressure cut-outs and oil pressure

cut-outs.

6MTechnical

12. Electric

motor.

Lubricate according to

manufacturer's instructions. Check

full load current.

(See also MOTORS)12M 12. Electric

motor.


manufacturer`s instructions. Check

full load current.

See also Motors SFG39-0112MTechnical

A) Normal

systems:

<3 kg

Check for oil and refrigerant leaks.



0MAdded

B) 3 kg to 30 kg Check for oil and refrigerant leaks.



12MAdded

C) 30 kg to 300 kg Check for oil and refrigerant leaks.



6MAdded

D) >300 kg Check for oil and refrigerant leaks.



3MAdded

E) Hermetically

sealed systems:

<6 kg




0MAdded

F) 6 kg to 30 kg Check for oil and refrigerant leaks.



12MAdded

Page 107 of 614

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Reason For

Change

G) 30 kg to 300 kg Check for oil and refrigerant leaks.



6MAdded

H) >300 kg Check for oil and refrigerant leaks.



3MAdded

Page 108 of 614

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COMPRESSOR - SCREW12-02 12-02 COMPRESSOR - SCREW




maintenance.






Added


A) Normal

systems:

<3 kg




0MAdded




12MAdded




6MAdded




3MAdded

E) Hermetically

sealed systems:

<6 kg




0MAdded




12MAdded




6MAdded




3MAdded

4. Leaks. Check for leaks should be part of


attendants.






Added

Page 109 of 614

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COMPRESSORS REFRIGERATION - CENTRIFUGAL - R 11/R 12

REFRIGERANT OR THEIR SUBSTITUTES R123/134a

12-03 12-03 COMPRESSORS REFRIGERATION - CENTRIFUGAL

Note:- More frequent maintenance checks should be carried out by the plant operators and local

maintenance personnel.

More frequent maintenance checks should be carried out by the client and local maintenance

personnel.




maintenance.






Technical




attendants.






Added

17. Cooling

tower.

Check settings of cooling tower fan

controls.

See HEAT REJECTION. Check

water treatment and make up

supply. Clean all water strainers.

12M 17. Cooling

tower.

Check settings of cooling tower fan

controls.

See Heat rejection SFG30-01

Check water treatment and make up

supply. Clean all water strainers.

12MTechnical

18. Motors -

hermetic. open.

Carry out electrical insulation tests.

Check air impeller or water cooling

coil is clean and efficient. Check

motor and compressor alignment.

Ensure that the liquid supply for

cooling the motor is adequate. If

appropriate remove filter and renew.

(See also MOTORS)

12M 18. Motors -

hermetic. open.

Carry out electrical insulation tests.

Check air impeller or water cooling

coil is clean and efficient. Check

motor and compressor alignment.

Ensure that the liquid supply for

cooling the motor is adequate. If

appropriate remove filter and renew.

(See also Motors 39-01)

12MTechnical

A) Normal

systems:

<3 kg




0MAdded




12MAdded




6MAdded




3MAdded

E) Hermetically

sealed systems:

<6 kg




0MAdded




12MAdded

Page 110 of 614

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Change




6MAdded




3MAdded

Page 111 of 614

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12-04 COMPRESSOR - SCROLL




maintenance.





Added


1. Compressor Oil Check compressor oil level. While the compressor is running,

the oil level may be below the sight

glass but still visible through the

sight glass. The oil level

should never be above the sight

glass.

Oil Appearance. If the oil is dark and

smells burnt, it was overheated

because of compressor operation at

extremely high condensing

temperatures, a compressor

mechanical failure, or occurrence of

a motor burnout. If the oil is black

and contains metal flakes, a

mechanical failure has occurred.

This symptom is often

accompanied by a high amperage

draw at the compressor motor.

If a motor burnout is suspected, use

an acid test kit to check the

condition of the oil. If a burnout has

occurred, test results will indicate an

acid level exceeding 0.05 mg

KOH/g.

1MAdded

2. Refrigerant

Charge

Check unit refrigerant charge by

measuring sub-cooling or visually

checking the sight glass for the

presence of bubbles.

1MAdded

3. Refrigerant

superheat

Check refrigerant superheat at the

compressor suction line. Superheat

should be in the range of 10°-20°F.

1MAdded

Page 112 of 614

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4. Compressor

phasing

Check compressor phasing. Proper phasing of the electrical

power is critical for proper operation

and reliability of the scroll

compressor. If the compressor

electrical phasing is incorrect, the

motor will draw low current, the

suction and discharge pressures will

change very little, and a rumble or

rattle may be heard.

The scroll compressor does not

have suction or discharge valves.

However, the symptoms for a phase

reversal are similar to those for a

valve failure.

1MAdded

5. Electrical With the unit disconnect switch

open, inspect the panel wiring. All

electrical connections should be

secure. Inspect the compressor

contactors. If the contacts appear

severely burned or pitted, replace

the contactor. Do not clean the

contacts.

12MAdded

6. General Remove any accumulation of dust

and dirt

from the unit.

12MAdded

7. Discahrge and

suction

With unit operating, check

refrigerant

discharge and suction pressures.

12MAdded



attendants.






Added

A) Hermetically

sealed systems:

<6 kg




0MAdded




12MAdded




6MAdded




3MAdded

Page 113 of 614

CONDENSERS

Page 114 of 614

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CONDENSERS - water cooled13-01 13-01 CONDENSERS - water cooled


4. Water strainers Check and clean. On open systems more frequent

cleaning will be necessary. Check

that condenser water is sterile

before opening any drains and

valves. Note: System could contain

legionella bacterium. Technician

should take suitable precautions.

12M 5. Water

strainers

Check and clean. On open systems more frequent

cleaning will be necessary. Check

that condenser water is sterile

before opening any drains and

valves. System could contain

legionella bacterium. Provider

should take suitable precautions.

12MOther

5. Condenser

Tubes.

Check condition, if dirty open. If

necessary clean with acid

treatment. Inspect for alkaline

deposits and/or corrosion.

If tubes are heavily scaled, refer to

water treatment contractor for

explanation as to why system is not

effective. Acid can be used for scale

removal by specialist if absolutely

necessary.

12M 6. Condenser

Tubes.

Check condition, if dirty open. If

necessary clean with a correctly

sized brush through the tubes. If

brushing does not successfully

clean the condenser consider acid

treatment. Regular use of acid will

reduce the working life of the tubes.

Inspect for alkaline deposits and/or

corrosion.

If tubes are heavily scaled, refer to

water treatment provider for

explanation as to why system is not

effective. Acid can be used for scale

removal by specialist if absolutely

necessary but can reduce the

thickness of the tube walls and

hence reduce life expectancy.

12MTechnical

6. Condenser

Shell.

Check for presence of

non-condensable gases, purge or

vent if necessary, but only if Legally

Qualified via Approved scheme..

Presence of non-condensable

gases will indicate a possible leak

on the vacuum side of the

refrigerant circuit. Take care not to

release CFCs.

12M 7. Condenser

Shell.

Check for presence of

non-condensable gases, purge or

vent if necessary, but only if legally

qualified via approved scheme..

Presence of non-condensable

gases will indicate a possible leak

on the vacuum side of the

refrigerant circuit. Do not release

refrigerant to atmosphere.

12MOther

7. Isolating

Valves.

Check external condition, leak

tightness of glands and seats,

operational spindles and

handwheels.

Repack as necessary.12M Deleted

8. Winter

Shutdown.

Isolate condensers and drain down. Seek advice from water treatment

specialist to protect from freezing.

12M 8. Winter

Shutdown.

Isolate condensers and drain down. Seek advice from water treatment

provider to protect from freezing.

Only shut down condensers where

the refrigeration and air conditioning

system has been shut down for the

winter.

12MTechnical

4. Isolating

Valves.



operational spindles and hand

wheels.

Repack as necessary.12MAdded

Page 115 of 614

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CONDENSER - air cooled13-02 13-02 CONDENSER - air cooled


4. Motor

Mountings.

Check for security and tightness. (See also MOTORS)12M 4. Motor

Mountings.

Check for security and tightness. (See also Motors SFG39-01)12MOther

5. Condenser

coil.

Inspect and clean. Test for

refrigerant leak and oil staining on

the end of the coils.

Check for damage to fins, comb out

and chemically clean if necessary.

Blow out with dry, oxygen free

nitrogen; only fully Competent

trained staff can do this work.

3M 5. Condenser

coil.

Inspect and clean. Test for

refrigerant leak and oil staining on

the end of the coils.

Check for damage to fins, comb out.

Blow out with dry, oxygen free

nitrogen. The unit can be

chemically clean if necessary,

however, this should be at the last

resort as the fins may be damaged

further by the acid. Only fully

Competent trained staff can do this

work.

3MOther

7. Sediment. Remove, if substantial build up has

occurred, investigate cause.

Substantial build up may indicate

significant corrosion and cause

should be identified.

3M Deleted

8. Alignment and

wear of belt drives,

where applicable.

Check pulley alignment and belt

wear.

Drive belt replacement intervals

need to be established.

3M 7. Alignment and

wear of belt drives,

where applicable.

Check pulley alignment and belt

wear.

Drive belt replacement intervals

need to be established.

3MOther

9. Head pressure

control damper.

Lubricate control damper bearings.6M 8. Head pressure

control damper.

Lubricate control damper bearings.6MOther

10. Air Filters. Check and replace if necessary.6M Deleted

11. Flexible

Connections.

Check and repair/replace as

necessary.

Report faults to client.12M 9. Flexible

Connections.

Check and repair/replace as

necessary.

Report faults to client.12MOther

12. Electrical

connections.

Check and tighten as necessary.

Check condition of flexible

conduits, wiring and insulation.

12M 10. Electrical

connections.

Check and tighten as necessary.

Check condition of flexible conduits,

wiring and insulation.

12MOther

13. Pipework. Inspect connections, pipes and

supports for damage, loose or

missing fittings. Repair as

necessary.

Report faults to client.12M 11. Pipework. Inspect connections, pipes and



necessary.

Report faults to client.12MOther

Page 116 of 614

CONTROL PANELS & CONTROLLERS

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INTRODUCTORY PROCEDURES14-01 14-01 CONTROL PANELS AND CONTROLLERS INTRODUCTORY

PROCEDURES

When working on or testing Control panels it is essential that all local and national statutory

regulations must be observed at all times. In the United Kingdom the Health and Safety at Work

etc. Act 1974 and the Electricity at Work Regulations 1989 are particularly relevant. It should be noted

that control panels having equipment operating above a nominal 415 Volts are excluded from this

specification. This does not imply that safety precautions are not be taken when working on

equipment above 415 volts

Care must be taken to make sure that all remote circuits associated with the switchgear are positively

isolated before any work is carried out. The isolation must be 'secure' that is it must either be at the

point of work or precautions must be taken to prevent anyone else switching on again when work is in

progress. A circuit, whether power or control must never be assumed to be 'dead' . Voltage tests must

always be carried out with proven test equipment. i.e. a voltage tester must first be checked on a

known live source immediately before use and again after use.

Whenever cables are disconnected from switchgear in the course of maintenance or replacement,

ensure that the cables are suitably insulated and marked for identification for reconnection.

Visually inspect to ensure plant is operating as expected. Check that any meters fitted show a correct

reading and any timers are set at the correct times for operation. Check readings against a known

Certified source.

Controllers, electrical and pneumatic control equipment

Electronic controllers and pneumatic equipment may be found in control panels and details regarding

maintenance schedules can be found in the appropriate sections of this schedule.

Appropriate safety guides are as follows:-

HSE Guidance Note GS38 1995, Electrical test equipment for use by electricians.

When working on or testing Control panels it is essential that all local and national statutory

regulations must be observed at all times. In the United Kingdom the Health and Safety at Work etc.

Act 1974 (www.hse.gov.uk), the Electricity at Work Regulations 1989 (www.hmso.gov.uk) and BS

7671:2008 Requirements for Electrical Installations - IEE Wiring Regulations 2008 are particularly

relevant. It should be noted that control panels having equipment operating above a nominal 415 Volts

are excluded from this specification. This does not imply that safety precautions are not be taken

when working on equipment above 415 volts.

Care must be taken to make sure that all remote circuits associated with the switchgear are positively

isolated before any work is carried out. The isolation must be `secure` that is it must either be at the

point of work or precautions must be taken to prevent anyone else switching on again when work is in

progress. A circuit, whether power or control must never be assumed to be `dead`. Voltage tests must

always be carried out with proven test equipment. i.e. a voltage tester must first be checked on a

known live source immediately before use and again after use. Care must also be taken as capacitors

can discharge high voltages when all other circuits have been isolated

Whenever cables are disconnected from switchgear in the course of maintenance or replacement,

ensure that the cables are suitably insulated and marked for identification for reconnection.

Visually inspect to ensure plant is operating as expected. Check that any meters fitted show a correct

reading and any timers are set at the correct times for operation. Check readings against a known

Certified source.

Controllers, electrical and pneumatic control equipment

Electronic controllers and pneumatic equipment may be found in control panels and details regarding

maintenance schedules can be found in the appropriate sections of this schedule.

Appropriate safety guides are as follows:-

HSE (www.hse.gov.uk) Guidance Note GS38 1995, Electrical test equipment for use by electricians.

Technical

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CONTROL PANELS - electrical services (excluding electrical controllers and

pneumatic relays)

14-02 14-02 CONTROL PANELS - electrical services (excluding electrical controllers and

pneumatic relays)

Before commencing any maintenance work on control panels, read introductory notes, very carefully

and follow all the safety procedures.

This task does not cover electrical controllers and pneumatic relays.

Before commencing any maintenance work on control panels, read Control panels and controllers

SFG 14-01 introductory notes, very carefully and follow all the safety procedures.

Technical


- direct on line. -

star delta - two

speed-dual wound

- two speed-pole

change - reversing

- auto tra

Various Types See

Notes

direct on line.

star delta

two speed-dual wound

two speed-pole change

reversing

auto transformer

Other

10. Busbar

systems.

Isolate supplies,inspect for signs of

overheating, or damage or burnt

out cables. Inspect mechanical

support systems and adjust fixings

if necessary.

Check all cable crimps for security

and fraying. Inspect crimp fasteners

for correct torque rating.

12M 10. Busbar

systems.

Isolate supplies, inspect for signs of

overheating, or damage or burnt

out cables. Inspect mechanical

support systems and adjust fixings

if necessary.

Check all cable crimps for security

and fraying. Inspect crimp fasteners

for correct torque rating.

12MOther

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CONTROL PANELS - lamps, meters, alarms etc.14-03 14-03 CONTROL PANELS - lamps, meters, alarms etc.


SFG 14 introductory notes, very carefully and follow all the safety procedures.

Added


1. Circuit. Check and energise to ensure that

the indicator is operational.

Replace any blown or discoloured

bulbs as required.

Replacement bulbs should be of the

correct type and the voltage, the

power rating must be as per the

manufacturer's specification. A

device of a higher power rating

should not be used.

1M 1. Circuit. Check and energise to ensure that

the indicator is operational. Replace

any blown or discoloured bulbs as

required.

Replacement bulbs should be of the

correct type and the voltage, the

power rating must be as per the

manufacturer`s specification.

1MOther

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OPTIMISER14-04 14-04 OPTIMISER

This schedule applies to all types of controllers and requires that all safety precautions and safe

working practices be observed.

1. Note all setpoints found.

2. Check mechanically for security of fixings, incoming cables, pneumatic pipework and terminal

connections for tightness.

3. Visually check controller for signs of damage. (i.e. ingress of dust or moisture).

4. Check all power, pneumatic air and supply tolerances as per manufacturer's recommendation, and

adjust as necessary.

5. Pneumatics. Pay particular attention to the quality of the instrument air. Check for

contamination by dirt, water or oil.



1. Note all set points found.






Other


1. Outside air

temperature

sensor.

Check outside sensor for

calibration and display accuracy.

This should be on a northerly wall

away from any direct or reflected

heat gains. Where this is not

possible, the sensor should be

mechanically shaded to give the

best result.

12M 1. Outside air

temperature

sensor.

Check outside sensor for calibration

and display accuracy. This should be on a northerly wall

away from any direct or reflected

heat gains. Where this is not

possible, the sensor should be

mechanically shaded to give the

best result.

12MOther

2. Inside air

temperature

sensor.

Check inside sensor for calibration

and display accuracy.

This should be placed in the coldest

chosen representative location,

ensure that it is free from any heat

gains or air movement restrictions.

12M 2. Inside air

temperature

sensor.

Check inside sensor for calibration

and display accuracy. This should be placed in the coldest

chosen representative location,

ensure that it is free from any heat

gains or air movement restrictions.

The design of the system may

incorporate more than one inside

sensor where an average

temperature is used for the

optimiser

12MTechnical

5. Battery. Check condition. Note the life expectancy (use by

date) and change at manufacturer's

recommendation. All batteries

should be disposed of only in

accordance with H&S and

Environmental regulations.

12M 5. Battery. Check condition and change as

required

Note the life expectancy (use by

date) and change at manufacturer`s





12MTechnical

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HEATING COMPENSATOR14-05 14-05 HEATING COMPENSATOR







4. Check all power, pneumatic air and supply tolerances as per manufacturer's recommendation and










4. Check all power supply tolerances as per manufacturer`s recommendation and adjust as

necessary.



Other


2. Outside air

temperature

sensor.

Check. This should be on a northerly wall

away from direct or reflected heat

gains. Where not possible, it should

have a mechanical shade.

12M 2. Outside air

temperature

sensor.

Check.

This should be on a northerly wall

away from direct or reflected heat

gains. Where not possible, it should

have a mechanical shade.

12MOther

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SINGLE INPUT CONTROLLER14-06 14-06 SINGLE INPUT CONTROLLER



Added

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necessary.

Before commencing any maintenance work on control panels, read SControl panels and controllers


Technical

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UNIT CONTROLLERS AND SENSOR CONTROLLERS14-07 14-07 UNIT CONTROLLERS AND SENSOR CONTROLLERS



Added

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4. Check all power, pneumatic air and supply tolerances as per manufacturer's recommendation, and










4. Check all power supply tolerances as per manufacturer`s recommendation, and adjust as

necessary.



Technical

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CONTROLLER TIMERS14-08 14-08 CONTROLLER TIMERS



Added


3. Battery. Check condition. Note the life expectancy (use by

date) and change at manufacturer's


should be disposed of in

accordance with H&S Environmental

REGULATIONS.

12M 3. Battery. Check condition and change as

required







12MTechnical

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Note: Timers are often built into the control panel. They can take the form of delay, run on, interval or

combinations of all three. The timer should be checked with reference to the control strategy.








necessary.

Note: Timers are often built into the control panel. They can take the form of delay, run on, interval or

combinations of all three. The timer should be checked with reference to the control strategy.



Technical

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STEP CONTROLLERS14-09 14-09 STEP CONTROLLERS



Added


4. Drive

motor/gear box.

Check operation in both directions. Where actuators are involved see

relevant section.

12M 4. Drive

motor/gear box.

Check operation in both directions. Where actuators are involved see

relevant section Actuators SFG

01-01.

12MTechnical

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necessary.



Technical

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TIMESWITCHES14-10 14-10 TIMESWITCHES



Added


1. Clocks. Check for satisfactory operation

and correct time.

Adjust for British Summer

Time/Greenwich Mean Time as

necessary.

12M 1. Clocks. Check for satisfactory operation

and correct time.

Adjust for British Summer


necessary.

6MOther

5. Monthly dial

settings e.g. for

solar time

switches.

Inspect and check. Replace battery at manufacturer's

recommendations.Batteries should

be disposed of in accordance with

H&S Environmental regulations.

12M 5. Monthly dial

settings e.g. for

solar time

switches.

Inspect and check. Replace battery at manufacturer`s

recommendations. Batteries should

be disposed of in accordance with

H&S

(www.hse.gov.uk/hthdir/noframes/co

shh/index.htm) Environmental

regulations.

12MOther

1. Time clocks. Check for satisfactory operation

and correct time.

Adjust time for British Summer


necessary.

12M 1. Time clocks. Check for satisfactory operation

and correct time.

Adjust time for British Summer


necessary.

6MOther

5. Battery back

up (if fitted).

Check condition. Replace battery according to

manufacturer's recommendations.

All batteries should be disposed of

in accordance with H&S


12M 5. Battery back

up (if fitted).

Check condition and change as

required







12MTechnical

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necessary.



Other

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MULTI-INPUT CONTROLLERS14-11 14-11 MULTI-INPUT CONTROLLERS



Added

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necessary.



Technical

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INDICATORS AND DISPLAYS14-12 14-12 INDICATORS AND DISPLAYS



Added

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ALARM MODULES14-13 14-13 ALARM MODULES



Added

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LEVEL CONTROLLERS14-14 14-14 LEVEL CONTROLLERS



Added

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necessary.



Technical

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SPEED CONTROLLERS14-15 14-15 SPEED CONTROLLERS

Electronic inverter type.

WARNING:- Due to the very high voltages present within this type of controller it is essential

that all safety precautions are strictly followed. The equipment must only be serviced by

competent and qualified personnel. The manufacturer's testing and maintenance procedures

including all safety precautions must be strictly followed.

Electronic inverter type

WARNING:- Due to the very high voltages present within this type of controller it is essential

that all safety precautions are strictly followed. The equipment must only be serviced by competent

and qualified personnel. The manufacturer`s testing and maintenance procedures including all safety

precautions must be strictly followed.



Technical


1. Overheating. Check for signs of overheating.12M 1. Overheating. Check for signs of overheating. Report any signs of over heating to

the client with proposed remedial

works

12MOther

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necessary.



Technical

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TRANSDUCERS - pneumatic to electronic and electronic to pneumatic14-16 14-16 TRANSDUCERS - pneumatic to electronic and electronic to pneumatic



Added

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14-17 DIRECT CURRENT [DC] DRIVES


1. Drive Clean all dust and foreign material

that can cause cooling problems,

cause corrosion and cause

problems with arcing.

12MAdded

2. Motor Check motor resistance and

connections see Motors SFG 39-01

Motors often exhibit changes in

resistance prior to failing.

12MAdded

3. Wiring Check and tighten [if loose] all

wiring connections.

12MAdded

4. Test Test that the power supplies have

not drifted out of tolerance. Check

the output waveforms at the

reference and feedback signals.

12MAdded

5. Signal wiring Verify signal wiring shielding is

properly terminated and the

connections are all tight.

Improper shielding can cause erratic

and intermittent behaviour of drive

equipment, and loose signal wiring

is a primary cause of drive

equipment downtimes.

12MAdded

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14-18 EMERGENCY STOP BUTTONS

Test all emergency stop devices. A wiring error or other problems may not be apparent until the

emergency stop device is tested. Push all buttons. Pull all pull cords, activate all emergency stop

devices. If any fail to create the emergency stop condition, count this as a failed test.

Once control power is back on, any any faults cleared, pressing the START button should result in the

machine / equipment restarting. This is correct and the test has been passed.

Added


1. Emergency

Stop buttons

Check correct operation of

Emergency Stop Buttons in

accordance with requirements of

PUWR Regulations.

If resetting the emergency stop

device results in control power

being re-applied, count this as a

failed test.

If you break or damage the machine

/ equipment while testing the

emergency stop system, count this

as a failed test. Advise Client.

3MAdded

2. Start function

test

Once the emergency stop device

has been activated, control power is

normally lost. Pressing any START

function on the control panel,

except POWER ON or RESET

should have no effect. If any aspect

of the machine / equipment starts,

count this as a failed test.

Advise Client.3MAdded

3. Power on or

reset test

Pressing POWER ON or RESET

before the activated emergency

stop device has been reset (i.e. the

e-stop button has been pulled out

to the `operate` position), should

have no effect. If you can turn the

power back on beofre you reset the

emergency stop device, count this

as a failed test.


4. Machine /

Equipment restart

test

Once the emergency stop device

has been reset, pressing POWER

ON or RESET should result in the

control power being restored. This

is acceptable. The machine /

equipment should not restart. If the

machine restarts normal operation,

count this as a failed test.


Page 143 of 614

DUCTING

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INTRODUCTORY PROCEDURES16-01 16-01 DUCTING AND AIR DISTRIBUTION INTRODUCTORY PROCEDURES

Ducting and air distribution

When installed, new ductwork must be certified clean and therefore not normally require internal

cleaning. However during use over a period, subject to use, a build up of deposits will occur

particularly at points where the velocity of the air reduces. Where filters are faulty, poorly installed

or maintained more rapid build up of dirt will occur. In normal circumstances, internal cleaning of

ducts would not be part of this specification but where the situation calls for remedial action, say for

example when previous maintenance was faulty or non existent, there has been a system usage

change or the plant has been left idle for a considerable period, the client should be informed, with a

recommendation that specialist cleaning should be undertaken as detailed in the HVCA Ventilation

Hygiene Guide to Good Practice (see TR/19)>

Special cleaning requirements such as are necessary in the pharmaceutical, food and process

industries are outside the scope of this specification and should be covered by special arrangements.

In kitchen extracts systems where access doors have been specifically provided for duct cleaning

purposes, the method and frequency of cleaning should be established and agreed with the client.

Sensors in ducts

When cleaning or working in ducts it is essential that all sensors or probes should be withdrawn from

the duct to prevent any damage.

Care should be also taken to prevent any damage to valves, linkages and other control devices which

may be located in a duct.

Where ducts are internally lined either for acoustic or insulation purposes inspection would normally

only be carried out if access doors are provided.

Ducting and air distribution

When installed, new ductwork must be certified clean and therefore not normally require internal

cleaning. However during use over a period, subject to use, a build up of deposits will occur

particularly at points where the velocity of the air reduces. Where filters are faulty, poorly installed or

maintained more rapid build up of dirt will occur. In normal circumstances, internal cleaning of ducts

would not be part of this specification but where the situation calls for remedial action, say for example

when previous maintenance was faulty or non existent, there has been a system usage change or the

plant has been left idle for a considerable period, the client should be informed, with a

recommendation that specialist cleaning should be undertaken as detailed in the B&ES (the Building

& Engineering Services Association, formerly the HVCA) Ventilation Hygiene Guide to Good Practice

(see TR/19)Special cleaning requirements such as are necessary in the pharmaceutical, food and

process industries are outside the scope of this specification and should be covered by special

arrangements.

In kitchen extracts systems where access doors have been specifically provided for duct cleaning

purposes, the method and frequency of cleaning should be established and agreed with the client.

(Ductwork cleaning SFG 17.01)

Other

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DUCTWORK SYSTEM - GENERAL16-02 16-02 DUCTWORK SYSTEM - GENERAL

Note:- Special requirements are necessary in the food and process industries, clean room

applications and kitchens

Special requirements are necessary in the food and process industries, clean room applications and

kitchens

Other


6. Ductwork

Support

Check all ductwork supports and

handers to ensure they are secure

and not loose

Report to client if remedial work

required.

12MAdded

7. Hit Hazards Inspect duct run where it runs

across or parallel to a personnel

access route. Highlight any low

points with the appropriate hazard

tape or paint

12MAdded

5. Internal

cleanliness.

Check internal condition through

sampling points (test points) where

fitted.

12M 5. Internal

cleanliness.

Check internal condition through

sampling points (test points) where

fitted.


required.

12MTechnical

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DUCTING - VOLUME CONTROL DAMPERS AND FIRE/ SMOKE DAMPERS16-03 16-03 DUCTING - VOLUME CONTROL DAMPERS AND FIRE/ SMOKE DAMPERS

Caution

All volume dampers are set up during commissioning and should not normally be subject to further

adjustment unless modifications are made to the ductwork distribution system. If it is essential to

move the damper for maintenance purposes extreme care should be taken to ensure that the damper

is returned to the position as set when commissioned. In the event of a ductwork modification, the

system should then be re-commissioned. Refer to HVCA TR/19 Section 3 for access requirements

and section 4 Para 4.19 & 4.20 for specific considerations.

Refer to HVCA publication DW145 for Fire Damper detail.

Typically a log of all dampers should be kept to record the results of the inspection , any

recommendations and any remedial work carried out.

Caution

All volume dampers are set up during commissioning and should not normally be subject to further

adjustment unless modifications are made to the ductwork distribution system. If it is essential to

move the damper for maintenance purposes extreme care should be taken to ensure that the damper

is returned to the position as set when commissioned. In the event of a ductwork modification, the

system should then be re-commissioned. Refer to B&ES (the Building & Engineering Services

Association, formerly the HVCA) TR/19 Section 3 for access requirements and Section 4 para 4.19 &

4.20 for specific considerations.

Refer to B&ES publication DW145 for Fire Damper detail.

Typically a log of all dampers should be kept to record the results of the inspection , any

recommendations and any remedial work carried out.

Technical


1. Volume control

dampers.

1. Visual check on condition.2.

Check position and ease of

movement and security of locking

devises.

The dampers should have the 'as

found' setting marked indelibly to

aid re-setting.Ensure that damper

opens and closes to desired

positions.

6M 1. Volume control

dampers.

1. Visual check on condition.

2. Check position and ease of

movement and security of locking

devises.

The dampers should have the `as

found` setting marked indelibly to

aid re-setting.

Ensure that damper opens and

closes to desired positions.

6MOther

2. Fire and

smoke dampers.


Check action and proper operation.

Inspect all dampers, apply a few

drops of oil to the mechanism.

Replace fusible links if required.

These may be subject to the

requirements of the local fire

brigade. Maintain a log of all

dampers tested, record faults and

any remedial action taken. This will

provide proof to the local fire

brigade that regular checks are

maintained. If any fire dampers are

inaccessible advise client.

6M 2. Fire and

smoke dampers.

1. Visual check on condition. If

damper is shut confirm that this is a

requirement of normal operation. (it

is possible that the fire damper may

have shut during a fire alarm

activation and has not been reset)

2. Check action and proper

operation. Inspect all dampers,

apply a few drops of oil to the

mechanism. Replace fusible links if

required.

These may be subject to the

requirements of the local fire

brigade. Maintain a log of all

dampers tested, record faults and

any remedial action taken. This will

provide proof to the local fire

brigade that regular checks are

maintained. If any fire dampers are

inaccessible advise client.

The dampers can accumulate dirt

which can affect their operation and

may require access panels added to

one or both sides to allow full

cleaning and surface restoration.

3MTechnical

3. Linkages on

motorised

dampers.


Check for wear and lubricate if

appropriate.

Please refer to notes on Item 1.

Volume control dampers.Ensure that

blades on shaft are secure and are

correctly aligned.

6M 3. Linkages on

motorised

dampers.

1. Visual check on condition.

2. Check for wear and lubricate if

appropriate.

Ensure that blades on shaft are

secure and are correctly aligned.

6MOther








information see CONTROL

PANELS.

6M 5. Electrical. Check for damage to flexible







information see Control panels and

controllers SFG14-01.

6MTechnical

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DUCTING - Acoustics16-04 16-04 DUCTING - Attenuators


3. Attenuators

(external

surfaces).

Clean, derust and repaint as

required.

For attenuators on COOLING

TOWERS see relevant section.

12M 3. Attenuators

(external

surfaces).

Clean, descale and repaint as

required.

12MTechnical

Page 148 of 614

DUCTWORK CLEANING

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DUCTWORK CLEANING HYGIENE, INSPECTIONS & MONITORING17-01 17-01 DUCTWORK CLEANING HYGIENE, INSPECTIONS & MONITORING

Note:- H&S Regulations apply and specific Risk Assessments will be required. A variety of specifically hazardous contaminants may be found in the ventilation systems , especially in

industrial or laboratory Local Exhaust Ventilation systems (LEV) whose performance falls under

COSHH regulations.

Reference Health and Safety at Work Regulations.

Technical


1. Ductwork. Ascertain age and date of last

clean

12M 1. Ductwork. Ascertain age and date of last

inspection.

12MOther

2. Ductwork

Hygiene.

Check internal condition by a

Deposit Thickness test or Vacuum

Test.

See HVCA Cleanliness of

Ventilation Systems ref. TR/19. If

inspection indicates a full cleaning

regime is required, inform client.

12M 2. Ductwork

Hygiene.

Check internal condition by a

Deposit Thickness test or Vacuum

Test.

Frequency to be determined by risk

assessment and testing regime as

per B&ES (the Building &

Engineering Services Association,

formerly the HVCA) Cleanliness of

Ventilation Systems ref. TR/19 and

BS EN 15780:2011 both of which

itemises the testing methods to be

adopted.

If inspection indicates a full cleaning

regime is required, inform client. If

the inspection reveals a build up of

moisture, identify the potential

source of moisture, inform client and

seek additional guidance from a

qualified Environmental Specialist

12MTechnical

3. Kitchen Extract

Ductwork.

Totally Clean. This is minimum cleaning interval,

heavy use, i.e. 12-16 hours per day

will necessitate a 3 monthly clean.

The exact timing will depend on a

range of factors, a new system

needs to be monitored to establish

the suitable minimum period.

12M 3. Kitchen Extract

Ductwork.

Clean in accordance with TR/19

section Section7.28 and 7.34.

This is minimum cleaning interval,

heavy use, i.e. 12-16 hours per day

will necessitate a 3 monthly clean

where light use i.e. 2-6 hours per

day will necessitate a 12 monthly

clean. The exact timing will depend

on a range of factors, a new system

needs to be monitored to establish

the suitable minimum period.

12MTechnical

Page 150 of 614

ELECTRICS IN BUILDINGS

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1 Specification

The specification covers the subjects of power supplies and associated electrical equipment up to 400

V, lighting, security and fire alarms, small scale power generation, communication systems and

provides an authoritative maintenance specification for these types of equipment. Regular

preventative maintenance is essential on electrical equipment as breakdowns can affect production ,

environmental conditions and energy wastage.

The maintenance frequencies shown in the schedules represent the intervals as recommended by the

HVCA and ECA, the actual frequencies will depend upon the particular application and should be

agreed with the client. It may be appropriate that certain elements of the maintenance programme

should coincide with planned shutdowns.

2. Safety

Fire prevention. Where electric cables pass through cabinets or walls it is standard practice to fit seals

to prevent the passage of smoke or flame. When maintaining cables, cabinets or junction boxes it is

essential that the integrity of the seals is maintained. Where a seal is replaced, it should comply with

the latest regulations.

Calibration of test equipment. The maintenance contractor should ensure that any test equipment has

been checked in accordance with the relevant British Standard.

3. Electrical Equipment

Attention is drawn to the necessity to comply with the requirements of the current Electricity at Work

Regulations in all aspects of work associated with the maintenance of electrical apparatus. Particular

attention is drawn to section 14.

All electrical equipment must be capable of local isolation and should be selected and erected in

accordance with BS 7671 - Regulations of the Institution of Electrical Engineers (IEE

Regulations).

4. Maintenance of Systems

The maintenance activity in respect of a system should be carried out by suitably qualified and

experienced staff, capable of exercising professional standards of judgement and discretion in relation

to individual systems. The specification is a statement of typical standards and further reference to

manufacturers should be sought for detailed guidance to supplement the specification.

There may be circumstances where maintenance is required on plant where operation is

continuous, i.e. industrial processes, ventilation equipment, environmental control, computer

installations or special situations. It is essential that in these circumstances control circuits

etc. should not be isolated or operated until specific instructions are received from the client.

Although polychlorinated biphenyls (PCB’s) (e.g. Pyrachlor and Askeral) are not longer used in

modern electrical equipment they may be present in older equipment, such as transformers and

capacitors. Extreme care should be taken with regard to their disposal and the appropriate statutory

regulations must be strictly followed.

5. Maintenance in Hazardous Areas

Certain areas such as those containing flame proof equipment, pharmaceutical laboratories, locations

subject to possible contamination by radiation, clean rooms, high risk fume cupboards and

inflammable risk situations call for specialist maintenance procedures which should be negotiated

individually with the client.

1. Specification

The specification covers the subjects of power supplies and associated electrical equipment up to 400

V, lighting, security and fire alarms, small scale power generation, communication systems and

provides an authoritative maintenance specification for these types of equipment. Regular

preventative maintenance is essential on electrical equipment as breakdowns can affect production ,

environmental conditions and energy wastage.

The maintenance frequencies shown in the schedules represent the intervals as recommended by the

HVCA (www.hvca.org.uk/) and ECA (www.eca.co.uk), the actual frequencies will depend upon the

particular application and should be agreed with the client. It may be appropriate that certain elements

of the maintenance programme should coincide with planned shutdowns.

2. Safety

Fire prevention. Where electric cables pass through cabinets or walls it is standard practice to fit seals

to prevent the passage of smoke or flame. When maintaining cables, cabinets or junction boxes it is

essential that the integrity of the seals is maintained. Where a seal is replaced, it should comply with

the latest regulations.

Calibration of test equipment. The maintenance contractor should ensure that any test equipment has

been checked in accordance with the relevant British Standard (www.bsi-global.com).

3. Electrical Equipment

Attention is drawn to the necessity to comply with the requirements of the current Electricity at Work

Regulations in all aspects of work associated with the maintenance of electrical apparatus. Particular

attention is drawn to section 14.

All electrical equipment must be capable of local isolation and should be selected and erected in

accordance with BS 7671 - Regulations of the Institution of Electrical Engineers (IEE (www.iee.org.uk)

Regulations).

4. Maintenance of Systems

The maintenance activity in respect of a system should be carried out by suitably qualified and

experienced providers, capable of exercising professional standards of judgement and discretion in

relation to individual systems. The specification is a statement of typical standards and further

reference to manufacturers should be sought for detailed guidance to supplement the specification.

While it is not always possible to rigidly follow a set procedure in every situation, guidance is given in

HSG 85 "Electricity at Work safe working practices" the following sequence is recommended as a

guide.

Identification - For most circuits and equipment correct labelling is important, but it should never be

assumed that labelling is correct and that work can be started without having first proved that the

equipment or circuit is dead. In some special cases, e.g. underground cables, cable locating

techniques using specialised instruments may be necessary and it may also be necessary to identify

the cable both before and after switching operations and cable spiking.

Disconnection - Disconnect the equipment from every source of electrical energy before working on,

or near, any part which has been live or is likely to be live.

Secure Isolation - To ensure adequate isolation, the disconnecting device should have an isolating

Technical

Page 152 of 614

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gap sufficient for the voltage levels present or likely to occur . Make sure that any switch disconnector

or other means of disconnection is secure. Switches should preferably be locked in the OFF position

using a ‘safety’ lock, i.e. a lock having a unique key. If a plug has been withdrawn, make sure that it

cannot be reconnected to the electrical supply while work is taking place on the circuits or apparatus.

If a fuse is removed, make sure that it or a similar one cannot be reinserted by taking it away or by

locking the box or enclosure until work is completed.

Post notices - Put a notice or label at the place of disconnection so everyone else knows that work is

being done.

Proving dead - Having isolated the circuit or equipment, check at the point of work that the parts to be

worked on or near really are dead, even if the isolation has been achieved automatically through an

interlocking system. If it is a three phase system or equipment with more than one supply, prove that

all supply conductors are dead. The device used for proving dead should itself be proved immediately

before and after testing.

Earthing - all the conductors are earthed using properly designed earthing devices or earthing leads,

usually applied to all points where the circuit or equipment is isolated from the supply.

Adjacent parts - When the circuit or equipment to be worked on has been made dead or where the

work is non-electrical, it may still be necessary to protect against inadvertent contact with other live

parts nearby.

There may be circumstances where maintenance is required on plant where operation is continuous ,

i.e. industrial processes, ventilation equipment, environmental control, computer installations or

special situations. It is essential that in these circumstances control circuits etc. should not be isolated

or operated until specific instructions are received from the client.

Although polychlorinated biphenyls (PCB’s) (e.g. Pyrachlor and Askeral) are not longer used in

modern electrical equipment they may be present in older equipment, such as transformers and

capacitors. Extreme care should be taken with regard to their disposal and the appropriate statutory

regulations must be strictly followed.

Asbestos – On older types of switchgear there is a risk that the arcshields may contain asbestos. The

asbestos register should be checked to see if there is any reference to the particular piece of

equipment due to be maintained. ALWAYS check for asbestos containing material prior to dismantling

any equipment. If asbestos, take actions in accordance with the Asbestos Regulations. Refer to

www.hse.gov.uk (www.hse.gov.uk) for detail.

5. Maintenance in Hazardous Areas

Certain areas such as those containing flame proof equipment, pharmaceutical laboratories, locations

subject to possible contamination by radiation, clean rooms, high risk fume cupboards and

inflammable risk situations call for specialist maintenance procedures which should be negotiated

individually with the client.

Page 153 of 614

EVAPORATORS

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EVAPORATORS19-01 19-01 REFRIGERATION EVAPORATORS


1. Compressor

full load operation.

Record inlet and outlet temperature

on water side. Pressure drop

across evaporator, refrigerant

pressures or superheat

temperatures and evaporator

temperature.

Any marked difference to the design

figures could indicate internal fouling

of the condenser and may require

additional work.

12MAdded

2. Flow

protection devices

Check for chilled water flow in the

system and correct operation.

12MAdded

3. Pump. Check and record pressure drop

across pump. Check for leakage,

bearing noise and unusual bearing

temperature. Lubricate according to

manufacturers instructions. Check

motor current.

For further guidance see Pumps

SFG 45-01

12MAdded

4. Automatic

Isolating Valves.



operational spindles and solenoid.

Some chillers have the ability to

automatically pump down refrigerant

to the evaporators in the event of a

refrigerant leak or other fault. For

further guidance see the

manufacturers instructions

12MAdded

2. Filter-Dryers Where fitted replace the filter

dryer(s) as required

check in line sight glass for

indication of moisture in system

6MAdded

7. Fans (if

applicable)


clean fan blades as required

For further guidance see Fans SFG

20

6MAdded

1. Tank/shell. Check external and internal

condition including baffles and

covers.

Liquid level for water cooling, brine

or glycol systems should be noted

and any leaks investigated.

12M 5. Tank/shell. Check external and internal

condition including baffles and

covers.

Liquid level for water cooling, brine

or glycol systems should be noted

and any leaks investigated and

repaired

12MOther

2. Valves and

drains.


tightness of glands and seats.

Ensure valve caps are tight and

secure. Check operation.

12M 6. Valves and

drains.


tightness of glands and seats.

Ensure valve caps are tight and

secure. Check operation.

For further guidance see Valves

SFG 61

12MTechnical

3. Pipes and

connections.

Check external condition and leak

tightness.

12M 7. Pipes and

connections.


tightness.

12MOther

4. Bearers,

supports, holding

down bolts.

Check for security and tighten as

necessary.

12M 8. Bearers,

supports, holding

down bolts.

Check for security and tighten as

necessary.

12MOther

5. Insulation. Check for damage.12M 9. Insulation. Check for damage. Repair as required.12MOther

6. Frost

Protection.

Check regime including cables and

thermostats.

12M 10. Frost

Protection.

Check regime including cables and

thermostats. Where fitted check

that the defrost system is operating

satisfactorily

12MTechnical

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1. Leaks. Inspect for leaks.6M 1. Leaks. Inspect for leaks. Fore further guidance on the

refrigerant side of this task see

Compresors - refrigeration SFG 12

6MTechnical

2. Coil. Check condition and clean fins. Use a sterilising solution.6M 3. Coil. Check condition and clean fins. Use a sterilising solution.6MOther

3. Condensate

tray and drain.

Check and ensure drain clear.

Flush and sterilise if necessary.

6M 4. Condensate

tray and drain.

Check and ensure drain clear.

Flush and sterilise if necessary.

6MOther

4. Condensate

pump (if

applicable)

Check operation. Often this equipment may be

contaminated, clean and flush,

sterilise if necessary.

6M 5. Condensate

pump (if

applicable)

Check operation. Often this equipment may be

contaminated, clean and flush,

sterilise if necessary.

6MOther

5. Electric

Heaters.

Check condition and operation.6M 6. Electric

Heaters.

Check condition and operation.6MOther

Page 156 of 614

FANS

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Movement of air, other than by natural circulation, is achieved by means of fans which are

mechanically driven, hence before working on any fan the drive must be electrically isolated in

accordance with Health and Safety legislation.

Types of fan covered in this section include centrifugal, axial, propeller, mixed flow, bifurcated and fire

and smoke extract units. Because of their specialist nature and the hazardous circumstances of use,

fans associated with fume cupboards, radioactive and nuclear facilities and biological and clinical

areas require specialist attention which is outside the scope of this specification.

Health and Safety

1. Access and Guards

It is dangerous to remove or open access doors, shaft guards, belt guards or remove any section of

the fan casing whilst the fan is running. It should be noted that any fans which are supplied as bare

shaft units must be guarded to BS 5304 before start-up.

2. Erosion and/or Corrosion

Where fans operate in an erosive or corrosive atmosphere, the fan rotating assembly must be

inspected at regular intervals (not exceeding six months) as dictated by plant operating conditions to

ensure safe operating conditions.

In addition to checking for component wear, an additional visual check should cover welds. If cracking

appears or is suspected, detailed non-destructive testing (NDT) of all impeller welds should be carried

out immediately. If cracking is confirmed the wheel should be removed from service for repair or

replacement

3. Access

Where fan access cannot be readily obtained, it is the responsibility of the client to provide access

facilities which comply in full with the requirements of any Health and Safety at Work legislation .

Movement of air, other than by natural circulation, is achieved by means of fans which are

mechanically driven, hence before working on any fan the drive must be electrically isolated in

accordance with Health and Safety (www.hse.gov.uk) legislation.

The isolator should be locked in the off position when maintenance takes place .

Types of fan covered in this section include centrifugal, axial, propeller, mixed flow, bifurcated and fire

and smoke extract units. Because of their specialist nature and the hazardous circumstances of use,

fans associated with fume cupboards, radioactive and nuclear facilities and biological and clinical

areas require specialist attention which is outside the scope of this specification.

General

If the system incorporates two fans, one for regular use and the second for back-up use if the primary

unit should fail, it is essential that both units be used and that similar levels of maintenance are

applied to both units.

After cleaning and servicing the fan, a label should be placed on the fan housing with details of the

current service date and any

relevant contact information. The label should also indicate the date at which the next routine

maintenance inspection is due.

Health and Safety

1. Access and Guards

It is dangerous to remove or open access doors, shaft guards, belt guards or remove any section of

the fan casing whilst the fan is running. It should be noted that any fans which are supplied as bare

shaft units must be guarded to BS (www.bsi-global.com) 5304 before start-up.

2. Fan rotation

It is essential to note that even when electrically isolated, some fans can have a tendency to rotate

under the action of the ventilation. It is therefore recommended that impellers are locked with integral

brakes (if fitted) or other means if no brake exists.

3. Erosion and/or Corrosion

Where fans operate in an erosive or corrosive atmosphere, the fan rotating assembly must be

inspected at regular intervals (not exceeding six months) as dictated by plant operating conditions to

ensure safe operating conditions.

In addition to checking for component wear, an additional visual check should cover welds. If cracking

appears or is suspected, detailed non-destructive testing (NDT) of all impeller welds should be carried

out immediately. If cracking is confirmed the wheel should be removed from service for repair or

replacement

4. Access

Where fan access cannot be readily obtained, it is the responsibility of the client to provide access

facilities which comply in full with the requirements of any Health and Safety at Work legislation .

Technical

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FANS - VENTILATING - general20-02 20-02 FANS - VENTILATING - general

The instructions in the table below refer to all air handling fans including exhaust, make up,

recirculation and small air handlers. Before working on any moving machinary switch off and ensure

that the equipment is isolated electrically in accordance with Health and Safety at Work Regulations.

Ensure to read health and safety notes shown on SFG 20-01 before undertaking the following tasks.


recirculation and small air handlers. Before working on any moving machinery switch off and ensure

that the equipment is isolated electrically in accordance with Health and Safety at Work

(www.hse.gov.uk) Regulations.

The isolator should ideally be locked in the off position when maintenance takes place .

Other


1. Bearings.

(`sealed for life'

bearings should

not be serviced).

Inspect and lubricate as necessary. Check bearings for end play and

wear.

6M 1. Bearings. Sealed for life` bearings should not

be serviced.

Inspect and lubricate as necessary.

Where applicable, all set-screws in

bearings should be checked and

tightened.

Check bearings for end play and

wear. Report any faults to the client.

If lubricators are provided,

re-lubrication should not exceed a

period of two years. When carrying

out re-lubrication it is essential that

every trace of water and dirt is

removed from around the grease

nipple. If the operating temperature

is over 60o C a shorter re-lubricating

period will be necessary. Ensure

that the correct oils and/or greases

and quantities are used. It is

particularly important that lubricants

of the correct working range are

used. Oil attracts dust and as a

consequence any excess should be

wiped clear (e.g. fan blades) see

manufacturer`s instructions.

6MTechnical

2. Housing. Clean and inspect for looseness

and corrosion.

6M 2. Housing. Clean and inspect for looseness

and corrosion.

Re-paint with a suitable corrosion

resistant paint as required.

6MTechnical

3. Drives and

belts.

Inspect, check condition and

alignment of drive and shaft. Adjust

or replace if condition warrants it.

6M 3. Drives, guards

and belts.

Inspect, check condition and

alignment of drive and shaft.

Adjust or replace if condition

warrants it.

Check all guards are secure and in

place.

When a new belt (or a new fan) has

been installed, the belt should be

re-tensioned after two weeks in

order to take up any slackness

resulting from stretching.

Guards should be painted a suitable

colour, so that they stand out.

1MTechnical

7. Anti-vibration

mountings.

Check effectiveness.6M 7. Anti-vibration

mountings.

Check effectiveness. The rubber/neoprene can degrade

with age and use. Report any faults

to the client.

6MTechnical

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10. Motor and fan

blade - cleaning

Clean and inspect all grilles. Clean

all dirt from the outside of any

motor.

Clean fan blades. Check for

excessive imbalance.

If dirt builds up on a motor it can act

as insulation which causes the

motor to operate at elevated

temperatures, resulting in shortened

motor life can be shortened and

motors commonly burn-out of

motors.

An excessive build up of dust or

damage to the fan blade can add

imbalance causing excessive

vibration. This can lead to fatigue

and dangerous failure.

Dirt should be removed by cleaning

with suitable equipment.

Fan blades and louvers can be

cleaned with a brush and detergent.

The fan motor casing must be totally

enclosed to prevent water from

damaging motor windings. If the

motor is not totally enclosed, then it

must be removed and cleaned

separately before the housing is

cleaned. If using a brush or

high-pressure washer care must be

taken not to damage the impeller

blades.

6MAdded

11. Motors -

electrical

Check the electrical and thermal

overload protection for the

motor, and if the motor has a

resettable overload protection.

Check that it is fully operational.

6MAdded

12. Electrics A) Check circuit breakers manually

each month.

Examine wiring and other electrical

system components for signs of

deterioration, loose connections

and damage. Check all connections

are tight.

1MAdded

12. B) Clean any sensors re-calibrate if

found to be inaccurate.

6MAdded

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FANS -CENTRIFUGAL20-03 20-03 FANS -CENTRIFUGAL







Added


7. Motor and fan

blade - cleaning



motor.



6MAdded

8. Motors -

electrical






6MAdded

9. Electrics Check circuit breakers manually

each month.





are tight.

1MAdded

9. Electrics Clean any sensors re-calibrate if


6MAdded

1. Impeller and

spinnings.

Clean and ensure no build up of

dirt.

In very dusty environments or where

contaminants are present more

frequent cleaning may be

necessary. If possible avoid

scraping but if necessary carry out

lightly. With plastic impellers soapy

water is the most effective cleaner.

12M 1. Impeller and

inlet venturi.

Clean and ensure no build up of

dirt.

In very dusty environments or where

contaminants are present more


necessary. If possible avoid

scraping but if necessary carry out

lightly. With plastic impellers soapy

water is the most effective cleaner.

12MOther

2. Motor

assembly.

Inspect.12M 2. Motor

assembly.

Inspect and check for any loose

connections, fixings or cables

12MTechnical

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3. Motor

bearings. (`Sealed

for life' bearings

should not be

serviced).

Lubricate with recommended

lubricant at intervals noted on fan

nameplate.

When carrying out lubrication it is

essential that every trace of water or

dirt is removed from around the

grease nipple. (See also MOTORS).

3. Bearings. Sealed for life` bearings should not

be serviced.




tightened.






grease nipple. (See also Motors

SFG 39-01.

Ensure that the correct oils and/or

greases and quantities are used. It

is particularly important that

lubricants of the correct working

range are used. Oil attracts dust and

as a consequence any excess

should be wiped clear (e.g. fan

blades) see manufacturer`s

instructions.

Technical

5. Belt drive (if

fitted).

Check tension and adjust if

necessary. Replace if aligned

condition warrants it.

Ensure motor and drive and pulley

are correctly aligned otherwise

excessive wear will occur on the

sides of the belt.

6M 5. Belt drive and

guards (if fitted).

Check tension and adjust if

necessary. Replace if condition

warrants it. Check all guards are

secure and in place.


are correctly aligned otherwise

excessive wear will occur on the

sides of the belt.



6MOther

Page 162 of 614

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FANS- AXIAL20-04 20-04 FANS- AXIAL







Added


2. Motor

bearings. (`Sealed

for life' bearings

should not be

serviced).


lubricant at intervals noted on fan

nameplate.




grease nipple. (See also MOTORS).


be serviced.




tightened.






grease nipple. (See also Motors

SFG 39-01.









instructions.

3MTechnical

5. Belt guards

(where fitted).

Check these are free from dirt build

up, if necessary, clean.

6M 5. Belt guards

(where fitted).

Check these are free from dirt build

up, if necessary, clean. Check all

guards are secure and in place.



6MTechnical

6. Impeller,

variable pitch

mechanism.

Check that there is no excessive

movement at the wing root.

There should be no loss of grease

from wing roots. If there

is, dismantle impeler and seals.

replaced after lubricating bearings.

6M 6. Impeller,

variable pitch

mechanism.

Check that there is no excessive

movement at the wing root.

There should be no loss of grease

from wing roots. If there is,

dismantle impeller and seals.

replaced after lubricating bearings.

6MOther

9. Motor and fan

blade - cleaning



motor.



6MAdded

10. Motors -

electrical






6MAdded


each month.





are tight.

1MAdded

Page 163 of 614

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6MAdded

Page 164 of 614

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FANS - PROPELLER20-05 20-05 FANS - PROPELLER







Added


6. Motor and fan

blade - cleaning



motor.



6MAdded

7. Motors -

electrical






6MAdded


each month.





are tight.

1MAdded



6MAdded

Page 165 of 614

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2. Motor

bearings. (`sealed

for life' bearings

should not be

serviced).


lubricant.







nipple.(See also MOTORS). If the

operating temperature is over 60º C

a shorter re-lubricating period will be

necessary, see manufacturer's

instructions.


be serviced.




tightened.









nipple.(See also Motors SFG 39-01.

If the operating temperature is over

60o C a shorter re-lubricating period

will be necessary, see










instructions.

6MTechnical

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FANS-MIXED FLOW20-06 20-06 FANS-MIXED FLOW




that the equipment is isolated electrically in accordance withHealth and Safety at Work



Added


1. Impeller and

spinnings.

Clean and inspect. Take care not to disturb impeller

balance weights. Cleaning is best

carried out with warm soapy water

using soft brush. Other cleaners

may be used provided they are not

harmful to the paint or galvanised

finish.

6M 1. Impeller and

inlet venturi.

Clean and inspect. Take care not to disturb impeller

balance weights. Cleaning is best

carried out with warm soapy water

using soft brush. Other cleaners

may be used provided they are not

harmful to the paint or galvanised

finish.

6MOther

2. Motor

bearings. ('sealed

for life' bearings

should not be

serviced).


lubricant.








is over 60º C a shorter re-lubricating

period will be necessary, see

manufacturer's instructions.(See

also MOTORS).


be serviced.




tightened.












manufacturer`s instructions.(See

also Motors SFG 39-01).









instructions.

6MTechnical

4. Protection

guards and

automatic shutters.

Clean and check shutter blades for

ease of action.

In dirty or moist laden environment

more frequent inspection and

cleaning may be necessary.

6M 4. Protection

guards and

automatic

shutters.

Clean and check shutter blades for

ease of action.

In dirty or moist laden environment

more frequent inspection and

cleaning may be necessary. Guards

should be painted a suitable colour,

so that they stand out.

6MTechnical

6. Roof cowl

intake/wall entry

louvre (where

applicable).

Clean and check mounting.6M 6. Roof cowl

intake/wall entry

louver (where

applicable).

Clean and check mounting. Where maintenance requires

working at height, ensure all

necessary precautions are taken to

prevent falls from a height. Working

at Height Regulations apply.

6MTechnical

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8. Motor and fan

blade - cleaning



motor.



6MAdded

9. Motors -

electrical






6MAdded


each month.





are tight.

1MAdded



6MAdded

Page 168 of 614

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FANS-BIFURCATED20-07 20-07 FANS-BIFURCATED

Note:- This type of fan, axial with the motor outside of the airstream, is normally used for fume

extracts e.g. kitchens, fire and smoke extraction and for fume removal particularly where corrosive.

This type of fan, axial with the motor outside of the airstream, is normally used for fume extracts e.g.

kitchens, fire and smoke extraction and for fume removal particularly where corrosive.




that the equipment is isolated electrically in accordance withHealth and Safety at Work



Other


13. Motor and fan

blade - cleaning



motor.



6MAdded


each month.





are tight.

1MAdded



6MAdded

3. Lubrication.

(`Sealed for life'

bearings should

not be serviced).

Check and lubricate if necessary

according to the manufacturer's

instructions.

If working in a high temperature

environment, more frequent

lubrication may be necessary.


be serviced.




tightened.





















instructions.

3MTechnical

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4. Standby motor

(where provided).

Check and rotate a few turns by

hand or electrically.

Units designed for emergency use

should be test operated for no

longer than twenty minutes.(See

also MOTORS).

3M 4. Standby motor

(where provided).

Check and rotate a few turns by

hand or electrically.

Units designed for emergency use

should be test operated for no

longer than twenty minutes.(See

also Motors SFG 39-01).

3MOther

6. Belt drive (if

fitted).

Check wear, alignment and tension. Replace if cording becomes visible.6M 6. Belt drive and

guards (if fitted).

Check wear, alignment and tension.

Check all guards are secure and in

place.

Replace if cording becomes visible.



6MTechnical

7. Automatic

shutters (usually

fitted on roof

units).

Clean and check operation. In moist or dirty environments more

frequent servicing may be required.

6M 7. Automatic

shutters (usually

fitted on roof

units).

Clean and check operation. In moist or dirty environments more

frequent servicing may be required.

Where maintenance requires

working at height, ensure all

necessary precautions are taken to

prevent falls from a height. Working

at Height Regulations apply

6MTechnical

9. Ductwork

including fixings

and insulation

(where fitted).

Inspect external condition and

report.

With kitchen extracts heavy deposits

of grease may be encountered and

more frequent inspection will be

necessary and client should be

informed of fire risk and a schedule

of cleaning drawn up. See

DUCTWORK HYGIENE.

12M 9. Ductwork

including fixings

and insulation

(where fitted).

Inspect external condition and

report.

With kitchen extracts heavy deposits

of grease may be encountered and

more frequent inspection will be

necessary and client should be

informed of fire risk and a schedule

of cleaning drawn up. See Ductwork

hygiene SFG 17-01.

12MOther

10. Motor. Check full load current and log.12M 10. Motor. Check full load current and log.






12MOther

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FANS-EXTRACT - including fire/smoke extracts units20-08 20-08 FANS-EXTRACT - including fire/smoke extracts units







Added


4. Fan and

motor. (`Sealed

for life' bearings

should not be

serviced).



See also MOTORS.6M 4. Bearings. Sealed for life` bearings should not

be serviced.




tightened.









nipple. See also Motors (SFG

39-01).









instructions.

6MTechnical

9. Motor and fan

blade - cleaning



motor.



6MAdded

10. Motors -

electrical






6MAdded


each month.





are tight.

1MAdded



6MAdded

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FIRE ALARMS - Associated Equipment22-02

Page 172 of 614

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FIRE ALARMS - Associated Equipment22-02

Page 173 of 614

FILTERS

Page 174 of 614

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Removal of dust and other non-gaseous matter in airborne streams is carried out by some form of

filter or device such as electrostatic precipitation. Where the air passes through the filter a back

pressure is set up which increases as the pores of the filtration medium become filled with the

particles removed from the air stream, the dirtier the air stream the more quickly the back pressure

builds up and the more frequently the filter has to be cleaned or changed. The maintenance periods

given in the tables below refer to average air conditions, in a dirty environment more frequent

maintenance will be required.

When replacing filters the same grade of filter should be used unless the client specifies differently .

Failure to do this or fitting filters of a lower specification will lead to poor performance e.g. black

markings on ceilings and near grilles. Ineffective filters will mean that FAN COILS will require more

frequent cleaning and accumulation of dust and debris in the ventilation system could give rise to a

fire hazard and clog automatic fire dampers

Filter replacements should comply with Eurovent 4/5

In normal use, air filters do not present a health and safety hazard. However used air filters do contain

quantities of dust which, unless precautions are taken, may expose maintenance personnel to a

`nuisance dust hazard', as defined by the Control of Substances Hazardous to Health (COSHH)

Regulations. A risk assessment must be carried out before the work starts and a method statement

produced. PPE may be needed.

Types of filters covered in this section include roll band, disposable panel, re-usable/disposal, bag,

cartridge and electrostatic. Because of their specialist nature and the hazardous circumstances of

their use certain filters require specialist attention which is outside the scope of this specification.

These include active carbon, cyclonic and inertia filters, wet, dry dust collectors and filters associated

with fume cupboards, radioactive, nuclear facilities, biological and clinical areas.

Removal of dust and other non-gaseous matter in airborne streams is carried out by some form of

filter or device such as electrostatic precipitation. Where the air passes through the filter a back

pressure is set up which increases as the pores of the filtration medium become filled with the

particles removed from the air stream, the dirtier the air stream the more quickly the back pressure

builds up and the more frequently the filter has to be cleaned or changed. The maintenance periods

given in the tables below refer to average air conditions, in a dirty environment more frequent

maintenance will be required.

When replacing filters the same grade of filter should be used unless the client specifies differently .

Failure to do this or fitting filters of a lower specification will lead to poor performance e.g. black

markings on ceilings and near grilles. Ineffective filters will mean that FAN COILS will require more

frequent cleaning and accumulation of dust and debris in the ventilation system could give rise to a

fire hazard and clog automatic fire dampers.

Filter replacements should comply with BS EN 779 Primary Filters G4 and secondary filters F5

In normal use, air filters do not present a health and safety hazard. However used air filters do contain


`nuisance dust hazard`, as defined by the Control of Substances Hazardous to Health (COSHH

(www.hse.gov.uk/hthdir/noframes/coshh/index.htm)) Regulations. A risk assessment must be carried

out before the work starts and a method statement produced. Used filters must be regarded as

Controlled Waste and appropriate safeguards taken for their disposal .

Types of filters covered in this section include roll band, disposable panel, re-usable/disposal, bag,

cartridge and electrostatic. Because of their specialist nature and the hazardous circumstances of

their use certain filters require specialist attention which is outside the scope of this specification.

These include active carbon, cyclonic and inertia filters, wet, dry dust collectors and filters associated

with fume cupboards, radioactive, nuclear facilities, biological and clinical areas.Technical

Other

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FILTERS21-02 21-02 AIR FILTERS

Note: - In normal use air filters do not present a health and safety hazard. However used air filters do

contain quantities of dust which, unless precautions are taken, may expose maintenance personnel to

a `nuisance dust' hazard, as defined by the `Control of Substances Hazardous to Health (COSHH)

Regulations'. A risk assessment must be carried out before the work starts and a method statement


Used filters should be sealed into plastic bags for disposal. ENVIRONMENTAL REGULATIONS apply.

In normal use air filters do not present a health and safety hazard. However used air filters do contain


`nuisance dust` hazard, as defined by the `Control of Substances Hazardous to Health (COSHH

(www.hse.gov.uk/hthdir/noframes/coshh/index.htm)) Regulations`. A risk assessment must be carried

out before the work starts and a method statement produced. Used filters should be sealed into

plastic bags for disposal. Controlled Waste Regulations apply.

Visual inspection of air filters is a the basic first action. If they are clearly dirty then they can be

changed and form part of a preventative planned maintenance program. (PPM). A better method for

filter change is based on filter change by noting increased operating pressure across the filter. When

the filter pressure is twice the initial value it is time to change. Where possible Low Energy Air Filters

should be selected so that running costs and energy use are minimised. Regular monitoring and

recording of pressure drop readings and recording of filter changes is to be encouraged.

The frequency of duct cleaning will depend upon the degree of contamination.

BS EN 15780:2011 gives three levels of cleanliness for typical applications;

Low - rooms with only intermittent occupancy e.g.

storage rooms, technical rooms.

Medium - offices, hotels, restaurants, schools,

theatres, residential homes, shopping

areas, exhibition buildings, sport buildings,

general areas in hospitals and general

working areas in industries.

High - Laboratories, treatment areas in hospitals

high quality offices.

Filter recommended inspection intervals according to the above cleanliness quality classes are; Low

and Medium 12 months and high is 6 months.

Technical


1. Air flow. Stop any air flow to filter.12M 1. Air flow. Stop any air flow to filter by turning

off the AHU system fan.

12MOther

3. Filter housing. Thoroughly clean including

surrounding ductwork and floor.

12M 3. Filter housing. Thoroughly vacuum and clean

including surrounding ductwork and

floor.

12MTechnical

5. Replacement. Ensure that edges are adequately

sealed to prevent ingress of dirty

air.

Spare fillers should not be unpacked

until required. Replacement is

required when air volume flow drops

to 0.5” above initial settings.

12M 5. Replacement. Ensure that filter header frames are

adequately sealed when fitted to

the mounting frames to prevent

bypass of dirty unfiltered air. Keep

a record card on each AHU

recording filter change time and

operating pressure drop at regular

intervals. Ensure that the filter is

installed the correct way around to

face the direction of the air flow.

Bag filters should have pockets in

vertical orientation.

Air filters should be selected to

deliver clean Indoor Air Quality

(Minimum F7 as EN13779:2007) in

inhabited environments. To minimise

energy usage filters should have a

low operating pressure drop. Filter

media should have a consistent

particulate efficiency. Spare filters

should remain sealed, packed and

in a dry environment until required.

Replacement is advised when the

initial operating pressure drop of the

filter doubles (assuming constant

volume flow. Eg. Initial pressure

drop 110Pa. Change at 220Pa.

12MTechnical

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1. Filter elements. Remove and replace at

manufacturer's recommended final

airflow pressure. Ensure that any

spillage or dust is vacuumed away.

Filters may have to be removed

more frequently depending upon

site conditions and operating hours.

After removal, used filters should be

sealed into plastic bags for disposal.

Do not attempt to wash or clean

out and reuse.

12M 1. Filter elements. Filters may have to be removed

more frequently depending upon

site conditions and operating hours.

Change filters on pressure drop

where possible. After removal, used

filters should be sealed into plastic

bags for disposal.

Do not attempt to wash or clean out

and reuse.

12MTechnical

1. Filter elements. Clean and replace as per


Filters may require more frequent

cleaning where the atmosphere is

heavily contaminated with dust or

fume.

12M 1. Filter elements. Clean and replace as per

manufacturer`s recommendations.

Filters may require more frequent

cleaning where the atmosphere is

heavily contaminated with dust or

fumes.

12MTechnical

2. Kitchen extract

grease filters.

Remove and clean as per


Frequency of cleaning can vary from

daily to weekly intervals. Generally

for grease filter panels the use of a

commercial dishwasher is possible.

Failure to change/clean filters

when loaded with grease may

result in the carry over of grease

ito the ducting - thus leading to

an increased hazard of a flash

over fire to the main ductwork.

See DUCTWORK HYGIENE.

12M 2. Kitchen extract

grease filters.

Remove and clean as per


Frequency of cleaning can vary from

daily to weekly intervals. Generally

for grease filter panels the use of a

commercial dishwasher is possible.

Failure to change/clean filters when

loaded with grease may result in the

carry over of grease into the ducting

- thus leading to an increased

hazard of a flash over fire to the

main ductwork. See Ductwork

cleaning SFG 17-01.

12MTechnical

e) Automatic roll

band type

e) Automatic roll

band type

Check roller mechanism is

operational

Consider conversion to bag filtersOther

1. Damage. Check and report if found. If found to be high this may indicate

either band velocity is too low or

wrong specification.

6M 1. Damage. Check and report if found. Try and

attribute damage to a cause.

If found to be high this may indicate

either band velocity is too low or

wrong specification.

6MOther

2. Differential

pressure.

Measure6M 2. Differential

pressure.

Measure using an accurate and

easy to read and maintain

instrument.

Take the opportunity to cross

reference readings and calibrate

pressure measuring device

regularly.

6MOther

3. Operation. Check for correct operation.6M 3. Operation. Check for correct operation. Look

for any splitting lacerations in the

media.

Sudden changes in operational

pressure drop across filters need

investigation.

6MOther

1. Condition. Check and clean. The frequency of cleaning will

depend upon the degree of

contamination. Failure to

change/clean filters when loaded

with grease may result in the

carry over of grease into the

ducting - thus leading to an

increased hazard of a flash over

fire to the main ductwork.See

DUCTWORK HYGIENE.

6M 1. Condition. Check and clean. Differentiate

between disposable grease filters

and those that are made to be

cleaned and reused.

The frequency of cleaning will

depend upon the degree of

contamination. Failure to

change/clean filters when loaded

with grease may result in the carry

over of grease into the ducting -

thus leading to an increased hazard

of a flash over fire to the main

ductwork. See Ductwork cleaning

SFG 17-01.

6MTechnical

g) High efficiency

- HEPA

The maintenance activities for these

depend on the individual installation

operating conditions. Reference

should be made to the

design/operating manuals for the

building.

g) High efficiency

- HEPA

Make sure air from supply system is

adequately filtered before reaching

the HEPA filters ensuring a longer

operating life. Regular validation of

the system may be required

depending on purpose of system.

The maintenance activities for these

depend on the individual installation

operating conditions. Reference

should be made to the

design/operating manuals for the

building.

Other

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ELECTROSTATIC FILTERS21-03 21-03 ELECTROSTATIC FILTERS

Note: - In normal use air filters do not present a health and safety hazard. However used air filters do

contain quantities of dust which, unless precautions are taken, may expose maintenance personnel to

a `nuisance dust' hazard, as defined by the `Control of Substances Hazardous to Health (COSHH)

Regulations'. A risk assessment must be carried out before the work starts and a method statement


Used filters should be sealed into plastic bags for disposal. ENVIRONMENTAL REGULATIONS apply

In normal use air filters do not present a health and safety hazard. However used air filters do contain


`nuisance dust` hazard, as defined by the `Control of Substances Hazardous to Health (COSHH

(www.hse.gov.uk/hthdir/noframes/coshh/index.htm)) Regulations`. A risk assessment must be carried

out before the work starts and a method statement produced.

Used filters should be sealed into plastic bags for disposal. Controlled Waste Regulations apply

Other


c) isolation, Isolate electrically in accordance

with HSAWA recommendations.

1M c) isolation, Isolate electrically in accordance

with HSAWA (www.hse.gov.uk)

recommendations.

1MTechnical

Page 179 of 614

FIRE ALARM SYSTEMS

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FIRE ALARM SYSTEM22-01 22-01 FIRE ALARM SYSTEM

Note: All tests on equipment and trigger devices should be recorded in the log book. Due to the

variety and complexity of fire alarms and associated systems they are not dealt with in detail in this

specification but the table below indicates the minimum requirements. Specialist back up may be

required either from the manufacturers or specialist contractors especially in connection with

intelligent systems. For further information see BS 5836, BS EN 54-2 and BS EN 54-4.

This section should be read in conjunction with the Daily and Weekly testing tasks .

A record of all tests and checks, and any defects remedied, should be maintained in the fire safety

manual / log book.

Arrangements should be made for all fire safety equipment, installations and systems (including fire

detection systems, automatic suppression systems, door control mechanisms, smoke control

systems, evacuation and fire-fighting lifts, emergency lighting, standby power systems, escalators,

and all passive fire protection provisions) to be inspected and tested on a regular basis by a

competent person. Alterations, additions, repairs or modifications to services and equipment should

be carried out only by competent persons.

Although modern fire alarm systems may incorporate a high degree of monitoring, so that faults are

indicated automatically, it is still necessary for the responsible person nominated by the user to ensure

that fault indications at the panel are identified for appropriate action. It is also vital for a regular test to

be carried out to ensure that there has not been any major failure of the entire system, or a significant

part of the system.

Routine testing of the system also provides an opportunity for occupants of the building to become,

and remain, familiar with the fire alarm signal(s) that the system produces. In systems with staged

alarms that incorporate an “Alert” and an “Evacuate” signal, both signals needs to be operated on the

occasion of each test to ensure that occupants are aware of the existence of both signals and their

different meaning.

The period between successive inspection and servicing visits should be based upon a risk

assessment, taking into account the type of system installed, the environment in which it operates and

other factors that may affect the long term operation of the system. If a risk assessment shows a need

for more frequent inspection and servicing visits, then all interested parties should agree the

appropriate inspection and servicing schedule. If this recommendation is not implemented, it should

be considered that the system is no longer compliant with this part of BS 5839.

All tests on equipment and trigger devices should be recorded in the log book. Due to the variety and

complexity of fire alarms and associated systems they are not dealt with in detail in this specification

but the table below indicates the minimum requirements. Specialist back up may be required either

from the manufacturers or specialist service providers especially in connection with intelligent

systems.

For further information see BS 5839 part 1 for fire detection and fire alarm systems, BS EN 54-2 and

BS EN 54-4.

The period between successive inspection and servicing visits should be based upon a risk

assessment, taking into account the type of system installed, the environment in which it operates and

other factors that may affect the long term operation of the system. If a risk assessment shows a need

for more frequent inspection and servicing visits, then all interested parties should agree the

appropriate inspection and servicing schedule. If this recommendation is not implemented, it should

be considered that the system is no longer compliant with this part of BS 5839

Technical


1.Operation. Check operation of all sounders

and external alarm links.

This action should include auxiliary

functions such as links with the main

gas valve, vent plant and all fault

warnings.

3M 1)Log Book The system log book should be

examined. It should be ensured that

any faults recorded have received

appropriate attention.

6MTechnical

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2.Condition. Check condition of equipment i.e.

ingress of moisture, damage or

other signs of deterioration.

The building occupier should inform

the maintenance engineer of any

structural or occupancy changes

which might affect the siting or

operation of the detector.

3M 2) Visual

Inspection

A visual inspection should be made

to check whether structural or

occupancy changes have affected

the compliance of the system with

the recommendations of this

standard for the siting of manual

call points, automatic fire detectors

and fire alarm devices.

Particular care should be taken to

verify whether:

1) all manual call points remain

unobstructed and conspicuous;

2) any new exits have been created

without the provision of an adjacent

manual call point;

3) any new or relocated partitions

have been erected within 500 mm

horizontally of any automatic fire

detector;

4) any storage encroaches within

300 mm of ceilings;

5) a clear space of 500 mm is

maintained below each automatic

fire detector and that the ability of

the detector to receive the stimulus

that it has been designed to detect

has not been impeded by other

means;

6) any changes to the use or

occupancy of an area makes the

existing types of automatic fire

detector unsuitable for detection of

fire or prone to unwanted alarms;

7) any building alterations or

extensions require additional fire

detection and alarm equipment to

be installed

The building occupier should inform

the maintenance engineer of any

structural or occupancy changes

which might affect the siting or

operation of the detector.

6MTechnical

3.Fireman's

control for vent

plant.

Check operation and log operation

of fans and dampers.

3M 3) False Alarms The records of false alarms should

be checked in accordance with

section 30.2i) of BS5839 part 1.

The rate of false alarms during the

previous 12 months should be

recorded. Action taken in respect of

false alarms recorded should

comply with the recommendations

of 30.2j) of BS5839 part 1

6MTechnical

4.Wiring and

equipment.

Visually inspect for damage and

integrity.

12M 4) Standby battery The standby battery should be

disconnected and full load alarm

should be simulated

6MTechnical

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5.Detectors

including photo

cells.

Check operation in accordance with

the manufacturer's

recommendations.

Inspect heat detectors for damage

or other condition, such as a heavy

coat of paint.

12M 5) Batteries Batteries and their connections

should be examined and

momentarily load tested with the

mains disconnected (other than

those within devices such as

manual call points, detectors and

fire alarm sounders of a

radio-linked system), to ensure that

they are in good serviceable

condition and not likely to fail before

the next service visit.

6MTechnical

6.Emergency

manual operated

systems.

Test operation. These devices should be tested

frequently by clients' operators.

3M 6) Fire Alarm

control and

Indicating

equipment

The fire alarm functions of the

control and indicating equipment

should be checked by the operation

of at least one detector or manual

call point on each circuit.

An entry should be made in the log

book indicating which initiating

devices have been used for these

tests.

6MTechnical

7.Completion of

test.

Reset all plant and gas valves after

test.

3M 7) Fire Alarm

devices

The operation of the fire alarm

devices should be checked.

6MTechnical

8.System test. Test in accordance with the relevant

regulations and rectify any defects.

BS 5839 should be followed.36M 8) Controls and

visual indicators

All controls and visual indicators at

control and indicating equipment

should be checked for correct

operation.

6MTechnical

9) Alarm signals The operation of any facility for

automatic transmission of alarm

signals to an alarm receiving centre

should be checked.

Where more than one form of alarm

signal can be transmitted (e.g. fire

and fault signals), the correct

transmission of each signal should

be confirmed.

6MAdded

10) Ancillary

functions

All ancillary functions of the control

and indicating equipment should be

tested.

6MAdded

11) Fault

indicators

All fault indicators and their circuits

should be checked, where

practicable, by simulation of fault

conditions.

6MAdded

12) Printers All printers should be tested to

ensure that they operate correctly

and that characters are legible.

It should be ensured that all printer

consumables are sufficient in

quantity or condition to ensure that

the printer can be expected to

operate until the time of the next

service visit.

6MAdded

13) Radio

Systems

Radio systems of all types should

be serviced in accordance with the

recommendations of the

manufacturer.

6MAdded

14) Manufacturers

checks and tests

All further checks and tests

recommended by the manufacturer

of the control and indicating

equipment and other components

of the system should be carried out.

6MAdded

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15) Completion On completion of the work, any

outstanding defects should be

reported to the responsible person,

the system log book should be

completed and a servicing

certificate should be issued.

6MAdded

a) The work described may be carried

out over the course of two or more

service visits during each twelve

month period

6MAdded

16) Manual Call

Points

The switch mechanism of every

manual call point should be tested,

either by removal of a frangible

element, insertion of a test key or

operation of the device as it would

be operated in the event of fire.

12MAdded

17) Automatic

detectors

All automatic fire detectors should

be examined, as far as practicable,

to ensure that they have not been

damaged, painted, or otherwise

adversely affected. Thereafter,

every detector should be

functionally tested. The tests used

need prove only that the detectors

are connected to the system, are

operational and are capable of

responding to the phenomena they

are designed to detect.

General :

Connections – check condition and

make good if necessary.

Mounting – Check security

12MAdded

18) Heat detectors Every heat detector should be

functionally tested by means of a

suitable heat source, unless

operation of the detector in this

manner would then necessitate

replacement of part or all of the

sensing element (e.g. as in fusible

link point detectors or

non-integrating line detectors).

Special test arrangements will

be required for fusible link heat

detectors. The heat source should

not have the potential to ignite a

fire; live flame should not be used,

and special equipment might be

necessary in explosive

atmospheres

12MAdded

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19) Point smoke

detectors

Point smoke detectors should be

functionally tested by a method that

confirms that smoke can enter the

detector chamber and produce a

fire alarm signal (e.g. by use of

apparatus that generates simulated

smoke or suitable aerosols around

the detector). It should be ensured

that the material used does not

cause damage to, or affect the

subsequent performance of, the

detector; the manufacturer’s

guidance on

suitable materials should be

followed.

12MAdded

20) Optical beam

smoke detectors

Optical beam smoke detectors

should be functionally tested by

introducing signal attenuation

between the transmitter and

receiver, either by use of an optical

filter, smoke or simulated smoke

12MAdded

21) Aspirating fire

detection systems,

VESDA system

Aspirating fire detection systems

should be functionally tested as

described in 45.4d of BS5839 part

1, with each sampling point, or

group of sampling points, in the

pipework of the system treated as a

point detector.

45.4d "Point smoke detectors

should be functionally tested by a

method that confirms that smoke

can enter the detector chamber and

produce a fire alarm signal (e.g. by

use of apparatus that generates

simulated smoke or suitable

aerosols around the detector). It

should be ensured that the material

used does not

cause damage to, or affect the

subsequent performance of, the


guidance on suitable materials

should be followed.

Not all test products may be

appropriate for the purpose

12MAdded

22) Carbon

Monoxide fire

detectors

Carbon monoxide fire detectors

should be functionally tested by a

method that confirms that carbon

monoxide can enter the detector

chamber and produce a fire alarm

signal (e.g. by use of apparatus that

generates carbon monoxide or a

gas that has a similar effect on the

electro-chemical cell as carbon

monoxide

It should be ensured that any test

gas used does not cause damage

to, or affect the subsequent

performance of, the


guidance on suitable test gases

should be followed.

12MAdded

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23) Flame

detectors

Flame detectors should be

functionally tested by a method that

confirms that the detector will

respond to a suitable frequency of

radiation and produce a fire alarm

signal. The guidance of the

manufacturer on testing of

detectors should be followed.

12MAdded

24) Analogue

values

In fire detection systems that

enable analogue values to be

determined at the control and

indicating equipment, it should be

confirmed that each analogue value

is within the range specified by the

manufacturer.

12MAdded

25) Multi-sensor

detectors

Multi-sensor detectors should be

operated by a method that confirms

that products of combustion in the

vicinity of the detector can reach

the sensors and that a fire signal

can be produced as appropriate

The guidance of the manufacturer

on the manner in which the detector

can be functionally tested effectively

should be followed

12MAdded

26) Visual devices All fire alarm devices should be

checked for correct operation. It

should be confirmed that visual fire

alarm devices are not obstructed

from view and that their lenses are

clean.

12MAdded

27) Filament

Lamps

All unmonitored, permanently

illuminated filament lamp indicators

at control and indicating equipment

should be replaced.

12MAdded

28) Radio signal Radio signal strengths in

radio-linked systems should be

checked for adequacy.

12MAdded

29) Cables A visual inspection should be made

to confirm that all readily accessible

cable fixings are secure and

undamaged.

12MAdded

30) Cause & Effect The cause and effect programme

should be confirmed as being

correct.

12MAdded

31) Standby

Power

The standby power supply capacity

should be checked to establish it

remains suitable for continued

service.

12MAdded

32) Shutters Operation - Check and ensure

action responds to appropriate

signals. Indicator lights - Check

operation and replace any faulty

lamps.

12MAdded

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33) Drop fire

curtains

Condition – Check for mechanical

damage.

Operation - Check operation and

control mechanisms

See relevant section Smoke extract

SFG 52

12MAdded

34) Magnetic door

latches


damage.


control mechanisms


SFG 52

12MAdded

35) Smoke relief

vents - Fireman`s

control for vent

plant

Check operation and log operation

of fans and dampers.

3MAdded

36) Smoke relief

vents


damage.


control mechanisms


SFG 52

12MAdded

37) Emergency

manual operated

systems.

Test Operation These devices should be tested

frequently by the clients’ operators

3MAdded

38) Interlocks Condition – Check for mechanical

damage.


control mechanisms.

Interlocks will be with heating,

ventilating and cooling equipment

and with fire extinguishing and other

systems , i.e. Smoke curtains SFG

52-04

12MAdded

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FIRE ALARMS - Associated Equipment22-02 22-02 FIRE ALARMS - Associated Equipment

TESTING: The client should carry out tests on equipment on a weekly basis in accordance with the

local fire regulations. Note: When carrying out maintenance any defects must be reported to the

client.

TESTING: The client should carry out tests on equipment on a weekly basis in accordance with the

local fire regulations. When carrying out maintenance any defects must be reported to the client.

Other


1.Decibel level. Check (see notes). The time period for checking

sounders should be agreed with the

client. Refer to BS 5839.

12M 1.Decibel level. Check (see notes). The time period for checking

sounders should be agreed with the

client. Refer to BS

(www.bsi-global.com) 5839.

12MOther

1.Condition. Check exterior and clean. Check and monitor according to


WARNING: Ionisation detectors

emit radiation, refer to manufacturer.

See SENSORS.

12M 1.Condition. Check exterior and clean. Check and monitor according to

manufacturer`s instructions. See

Sensors and switching devices SFG

50.

12MOther

1. Condition. Check condition and life. Check according to the



in accordance with statutory

requirements, COSHH .

12M 1. Condition. Check condition and life. Check according to the


12MOther

Chargers See POWER GENERATION. Chargers See Power generators SFG 43-0412MOther

Page 188 of 614

FIRE PROTECTION SYSTEMS

Page 189 of 614

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The need for preventive maintenance on fire prevention systems is essential but in negotiations

between contractor and client is vital that aspects of insurance, liability, compliance with regulations

etc. are fully agreed by both parties. Both the Loss Prevention Council requirements and local fire

regulations must be complied with and should any areas of doubt arise it is recommended that these

be fully discussed with the appropriate representative of the fire prevention bodies.

It is the duty of the contractor to ensure that he has taken out adequate insurance cover to meet all

the liabilities and requirements associated with the maintenance of fire protection systems and the

client should satisfy himself on this account.

Compliance with the relevant fire regulations is necessary for both the client and the contractor and

close liaison with the local fire protection officer should be maintained at all times

The Loss Prevention Council (now part of the BRE) has issued a comprehensive schedule of fire

prevention measures and these should be adopted by both the client and the contractor.

Sprinkler systems have not been included due to the complexity and variety of design, reference

should be made to the Care & Maintenance of Automatic Sprinkler Systems (TB203: 2004) published

by LPC.

The need for preventive maintenance on fire prevention systems is essential but in negotiations

between service provider and client is vital that aspects of insurance, liability, compliance with

regulations etc. are fully agreed by both parties. Both the Loss Prevention Council requirements and

local fire regulations must be complied with and should any areas of doubt arise it is recommended

that these be fully discussed with the appropriate representative of the fire prevention bodies.

It is the duty of the service provider to ensure that he has taken out adequate insurance cover to meet

all the liabilities and requirements associated with the maintenance of fire protection systems and the

client should satisfy himself on this account.

Compliance with the relevant fire regulations is necessary for both the client and the service provider

and close liaison with the local fire protection officer should be maintained at all times

The Loss Prevention Council (now part of the BRE) (www.bre.co.uk/frs) has issued a comprehensive

schedule of fire prevention measures and these should be adopted by both the client and the service

provider.

Other

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HOSE REELS PRESSURE BOOSTING SETS23-02 23-02 HOSE REELS PRESSURE BOOSTING SETS

If, due to unforeseen difficulties, an installation is left unavailable for use, the fire brigade must be

informed and again after reinstatement.

Where, due to unforeseen difficulties, it is necessary to leave an installation not available for use, the

fire and rescue service should be informed immediately in order that alternative arrangements can be

made to cover this deficiency should the need arise. In addition a suitable notice to indicate that the

installation is not available for use should be placed in a prominent position.

Technical


3. Pump and

motor alignment.

Check and adjust if necessary. Examine couplings for tightness.3M 3. Pump and

motor alignment.

Check and adjust if necessary,

ensure pump shafts are free to

rotate

Examine couplings for tightness.3MTechnical

4. Motor and

bearings.

Oil or grease where external

nipples or lubricators are fitted.

Use recommended grade of

lubricant. Motor should be

overhauled annually, see -

MOTORS.

3M 4. Motor and

bearings.





overhauled annually, see Motors

SFG 39

3MTechnical

10. Test run

pressure booster

sets, pressurising

units, and filling

pump.

Carry out adjustments to ensure

satisfactory operation.

Check operation of all automatic

controls and change-over switches,

including signal to BMS if fitted.

3M 10. Test run

pressure booster

sets, pressurising

units, and filling

pump.




controls and change-over switches,

including signal to BMS SFG 06. If

operating any booster set pumps in

the Hand position, there is a danger

that if there is NO FLOW in the pipe

work, damage to the mechanical

seals and/or impellers of the pumps

could occur. The Hand Position

should only be used for testing the

pumps or in an emergency situation.

3MTechnical

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HOSE REELS - Static or Swinging23-03 23-03 HOSE REELS - Static or Swinging

If, due to unforeseen difficulties, an installation is left unavailable for use, the fire brigade should be

informed and again after reinstatement.





Maintenance should be carried out in accordance with BS EN 671-3:2009

Leave the hose reel and hose system ready for immediate use; if any extensive maintenance is

necessary the hose reel or hose system shall be labelled "OUT OF ORDER" and the competent

person shall inform the user/owner.

Technical


9) Swinging reels Check that the movement is free

and that the reel swings minimum

required angles shown in BS EN

671 parts 1 & 2. Check condition of

‘O’ rings

If leakage is evident replace `O`

rings.

12MAdded

10a) Stop Valves

– Manual reels

check the manual stop valve is of

correct type and that it operates

easily and correctly

12MAdded

10b) Stop Valves

– Automatic reels

check the correct operation of the

automatic valve and check for the

correct operation of the isolating

service valve

12MAdded

11)Back flow

prevention devices

(check valves).

Check operation. Ensure that valve is seating

properly.

12MAdded

12) Notices Check that the location is clearly

marked and that the operating

instructions are clear.

12MAdded

13) Water flow Check that the flow of water is

steady and sufficient

12MAdded

14)Hose All hoses shall be pressurised to

maximum working pressure in

accordance with BS EN 671 parts 1

& 2

60MAdded

1. Condition. Completely run out reel, inspect

and subject to operational water

pressure test.

12M 1)Hose Completely run out reel, inspect

and subject to operational water

pressure test. Check that it is

unobstructed, that there is no

damage, components are not

corroded and that there are no

leaks.

The full length of hose must be

inspected for signs of cracking,

distortion, wear or damage; if the

hose shows any signs of defect it

must be replaced or proof-tested to

maximum working pressure;

12MLegislative

2. Back flow

prevention devices

(check valves).

Check operation. Ensure that valve is seating

properly.

12M 2)Brackets and

fixings

Check that the brackets for wall

mounting are secure.

12MLegislative

3. Couplings. Check and during wet testing check

for leakage.

12M 3) Cabinet If fitted with a cabinet check that the

doors open freely and that there is

no sign of damage.

12MLegislative

Page 192 of 614

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4. Swivel joints

(swinging hose

reels).

Check swinging movement is free,

condition of 'O' rings.

If leakage is evident replace 'O'

rings.

12M 4) Pipework and

couplings

Check the condition of the water

supply pipework and any couplings

pay particular attention to any

flexible pipework for corrosion,

damage or wear.

12MLegislative

5. Nozzles. Check functioning.12M 5) Nozzle Check they are of the correct type,

functioning and easy to operate

12MLegislative

6. Associated

equipment and

fittings.

Ensure glands, tubing, shut-off

nozzle are sound and free from

leaks. Check outlet of nozzle is

unobstructed.

12M 6) Hose clips or

bindings

Check they are securely fastened12MLegislative

7. Flow test. Test in accordance with the

requirements of the Loss

Prevention Council .

If it is not possible to test every reel,

at least the highest reel on each

rising main should be tested.

12M 7) Hose drums Check hose drum rotates freely in

both directions.

If it is not possible to test every reel,

at least the highest reel on each

rising main should be tested.

12MLegislative

8. Accessibility. Check and report to client

immediately if there are any

obstructions.

Hose reels and any associated

equipment should be accessible at

all times.

12M 8)Pressure gauge Check gauge (if fitted) are working

within their operating range and

working satisfactorily.

Hose reels and any associated

equipment should be accessible at

all times.

12MLegislative

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RISING FIRE MAINS and HYDRANTS23-04 23-04 RISING FIRE MAINS and HYDRANTS





Added


2. Wet test. Check for leaks.12M 2. Wet test. a) Check earthing arrangement and

ensure continuity between joints

b) Carry out physical check of the

system

c) Static pressure test – flush riser

by turning on water and allow to

flow out of topmost outlet.

d) Charge system to 10 bar

measured at the inlet for 15

minutes minimum. Check system

during this period for leaks etc.

e) Flow test – after static pressure

test a flow test should be carried

out if considered necessary.

f) Water should be passed through

system under pressure and flow

gauge readings recorded

If it is not possible to sustain an

effective fire-fighting jet from the

topmost outlet, or any undue

pressure loss in the rising main

(after allowing for the height

involved) should be investigated

12MTechnical

3. Booster

pumps.

Thoroughly check pumps and

associated mechanical and

electrical equipment.

For more detailed instructions see

PUMPS.

6M 3. Booster

pumps.

Thoroughly check pumps and

associated mechanical and

electrical equipment.

For more detailed instructions see

Pumps SFG 45.

6MTechnical

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HALON FIRE PROTECTION SYSTEMS23-05 23-05 Gas Extinguishing systems

HALON is a chloroflurocarbon and as such has been phased out of general use and has been

replaced by INERGEN because of the damaging effect HALON has on the upper atmosphere.

Where the installation is still legally permitted (Very Restricted), it is essential that leaks must be

prevented and residual material not discharged to the atmosphere. The client/user of the system

should check weekly, all pressure gauges, control settings and indicators. Such systems must only be

maintained and tested by qualified engineers as per the requirements of BS 5306: Part 5.

HALON is a chlorofluorocarbon and as such has been phased out of general use and has been

replaced by various other inert gases such as INERGEN because of the damaging effect HALON has

on the upper atmosphere.

All extinguishant removed from containers during service or maintenance procedures shall be

collected and recycled, or disposed of in an environmentally sound manner, and in accordance with

existing laws and regulations.

Inert gas mixtures based on those gases normally found in the earth`s atmosphere are exempted

from this requirement.

Weekly the client/user of the system should Visually check the hazard and the integrity of the

enclosure for changes which might reduce the efficiency of the system. Carry out a visual check that

there is no obvious damage to pipework and that all operating controls and components are properly

set and undamaged. Check pressure gauges and weighing devices, if fitted, for correct reading and

take the appropriate action specified in the users` manual.

Monthly the client/user of the system should check that all personnel who may have to operate the

equipment or system are properly trained and authorised to do so and, in particular, that new

employees have been instructed in its use.

Such systems must only be maintained and tested by qualified engineers and in accordance with BS

5306-0:2011 and BS EN 15004 part 1:2008

This task is applicable to the extinguishants listed below;

FK-5-1-12, HCFC Blend A, HCFC-123, HCFC-22, HCFC-124, HFC 125, HFC 227ea, HFC 23, IG-01,

IG-100, IG-55, IG-541





Technical


8) Master/slave

system.

Check slave actuation system

including pistons in pneumatic valve

actuators.

6MAdded

9) Auxiliary electric

device/ alarm,

door closures, etc.

Test operation. Operational test to be carried out in


recommended procedure.

6MAdded

10) Enclosure

Integrity test

Check the enclosure for any

boundary penetrations or other

changes to it that could affect

leakage of gas on operation. If this

can not be visually determined an

integrity test should be carried out.

Test should be carried out in

accordance with Annex E BS EN

15004-1:2008

Where the integrity test reveals

increased leakage that would result

in an inability to retain the

extinguishant for the required

period, remedial action shall be

carried out.

12MAdded

1. System. Check generally for mechanical

damage.

6M 1. Electrical

detection and

alarm systems

Test and service in accordance with

appropriate manufacturers’

standards.

3MLegislative

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2. Cylinders. check labels are securely fixed and

legible, check security of brackets

and fixings, check liquid level,

check pressure in cylinder(s).

Level is checked by weighting, if

weight loss exceeds 5% cylinder

should be replaced or recharged. If

pressure has fallen more than 10%

on a temperature corrected basis,

cylinder should be replaced or

recharged.

6M 2) System Check generally for mechanical

damage.

6MLegislative

3. Nozzles. Examine for blockages and clean

as necessary.

6M 3) Pipework &

Nozzles

Externally examine pipework to

determine its condition. Examine

nozzles for blockages and clean as

necessary

Replace or pressure test and repair

as necessary pipework showing

corrosion or mechanical damage

6MLegislative

4. Valve

actuators.

Where possible, remove cylinder

valve and replace action caps.

Carry out procedure in accordance

with the manufacturer's

recommendations.

6M 4) Control Valves check all control valves for correct

manual function and automatic

valves additionally for correct

automatic function

6MLegislative

5. Master/slave

system.


including pistons in pneumatic

valve actuators.

6M 5) Valve actuators. Where possible, remove cylinder




recommendations.

6MLegislative

6. Mechanical

integrity.

Test for mechanical tightness of

pipework and associated

equipment.

This is to prevent leakage of

HALON.(fire suppression agents.)

6M 6) Cylinders Check labels are securely fixed and




Externally examine containers for

signs of damage or unauthorized

modification, and for damage to

system hoses. If the visual

examination shows any defect, the

hose(s) shall be replaced.

For liquefied gases check weight or

use a liquid level indicator to verify

correct content of containers. If

weight loss exceeds 5% cylinder

should be replaced or recharged.

Pressure gauges –liquefied gas

should be within 10% and

non-liquefied gases within 5% of

correct pressure; replaced or

recharged any showing a greater

loss.

The date of inspection and the

name of the person performing the

inspection shall be recorded on a

tag attached to the container.

As required by statutory regulations

– remove cylinders and pressure

test when necessary.

6MLegislative

7. Auxiliary

electric device/

alarm, door

closures, etc.


accordance with manufacturer's


6M 7) Cylinder gauges Where container pressure gauges

or weight-monitoring devices are

used for this purpose, they shall be

compared to a separate calibrated

device

Operational test to be carried out in

accordance with manufacturer`s


12MLegislative

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CARBON DIOXIDE TOTAL FLOODING FIRE EXTINGUISHING SYSTEM23-06 23-06 CARBON DIOXIDE TOTAL FLOODING FIRE EXTINGUISHING SYSTEM

The client/user of the system should check weekly, all pressure gauges, control settings and

indicators. Such systems must only be maintained and tested by qualified engineers as per the

requirements of BS 5306: Part 5.

Such systems must only be maintained and tested by qualified engineers and in accordance with BS

5306-4:2001 and BS EN 15004 part 1:2008

During servicing every care and precaution shall be taken to avoid release of extinguishant.




installation is not available for use should be placed in a prominent position

Other


1. System. Check generally for mechanical

damage.

Report to client any defects or

incorrect installation.

6M 1. Electrical

detection and

alarm systems

Test and service in accordance with

appropriate manufacturers’

standards.

3MLegislative

2. Cylinders. Check labels are securely fixed and


and fixings, check liquid level

and check pressure in cylinder(s).

Level is checked by weighing, if

weight loss exceeds 5%, cylinder(s)

should be replaced or recharged. If

pressure has fallen more than 10%

on a temperature corrected basis,

cylinder(s) should be replaced or

recharged.

6M 2) System Check generally for mechanical

damage.

6MLegislative

3. Nozzles. Examine for blockages and clean

as necessary.

6M 3) Pipework &

Nozzles

Externally examine pipework to

determine its condition. Examine

nozzles for blockages and clean as

necessary

Replace or pressure test and repair

as necessary pipework showing

corrosion or mechanical damage

6MLegislative

4. Valve

actuators.

Where possible, remove cylinder



with the manufacturer's

recommendations.

6M 4) Control Valves Check all control valves for correct

manual function and automatic

valves additionally for correct

automatic function

6MLegislative

5. Master/slave

system.


including pistons in pneumatic

valve actuators.

6M 5) Valve actuators. Where possible, remove cylinder




recommendations.

6MLegislative

6. Mechanical

integrity.

Test for mechanical tightness of

pipework and associated

equipment.

6M 6) Cylinders Check labels are securely fixed and




Externally examine containers for

signs of damage or unauthorized

modification, and for damage to

system hoses. If the visual

examination shows any defect, the

hose(s) shall be replaced

Carbon Dioxide containers - check

weight or use a liquid level indicator

to verify correct content of

containers. If weight loss exceeds

10% cylinder should be replaced or

recharged.

Check contents of pilot containers.

Liquefied gas type should be within

10% and non-liquefied within 5% of

correct charge. Replace or recharge

any showing a greater loss.

The date of inspection and the

name of the person performing the

inspection shall be recorded on a

tag attached to the container.

As required by statutory regulations

– remove cylinders and pressure

test when necessary

6MLegislative

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7. Auxiliary

electric device/

alarm, door

closures, etc.


accordance with manufacturer's


6M 7) Cylinder gauges Where container pressure gauges

or weight-monitoring devices are

used for this purpose, they shall be

compared to a separate calibrated

device

Operational test to be carried out in

accordance with manufacturer`s


12MLegislative

8) Master/slave

system.


including pistons in pneumatic valve

actuators.

6MAdded

9) Auxiliary electric

device/ alarm,

door closures, etc.




6MAdded

10) Enclosure

Integrity test

Check the enclosure for any

boundary penetrations or other

changes to it that could affect

leakage of gas on operation. If this

can not be visually determined an

integrity test should be carried out.

Test should be carried out in

accordance with Annex A BS

5306-4:2001

Where the integrity test reveals

increased leakage that would result

in an inability to retain the

extinguishant for the required

period, remedial action shall be

carried out.

12MAdded

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EXPANSION FOAM SYSTEMS23-07 23-07 EXPANSION FOAM SYSTEMS

Note: The schedule shall be carried out by a competent person who will provide client with a signed

dated report.

Maintenance shall consist of measures necessary for ensuring that all parts of the foam system

remain in operating condition. The availability and reliability of the foam systems shall be assured.

Inspection and maintenance by an approved competent organisation is recommended. Such systems

must only be maintained and tested by qualified engineers and in accordance with BS EN

13565-2:2009 and BS EN 15004 part 1:2008





Technical


6) Pipework Visual check of pipework, foam

outlets, nozzles and pipe supports

for damage or deterioration

If visual indication of normally dry

pipework indicates questionable

strength due to corrosion or

mechanical damage, hydraulically

pressure test.

1MAdded

7) Frost protection Check frost protection for the

permanently charged pipework

system

1MAdded

8) Tanks Test automatic refill devices of

water tanks

1MAdded

9) Alarms Check of alarm signalling to a

permanent manned location in the

case of automatic released

extinguishing systems.

1MAdded

10) Air Inlet Check the air inlet opening of foam

generating devices/nozzles are free

from obstruction

1MAdded

11) Strainers Check and clean strainers6MAdded

12) Foam

concentrate

proportioner

Functionally test the foam

concentrate proportioner using

water without the use of foam

concentrate (where specified by the

manufacturer

6MAdded

13) Valves Test the free movement of all

valves and mechanically operated

components. Check for free

operation of stop valves.

6MAdded

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14) Foam

Concentrate

A check of the foam concentrate

properties shall be carried out by

competent and trained foam

laboratory

personnel. The sampling shall be

carried out according to the

manufacturer’s instructions.

The checks shall include; foam type,

specific gravity, PH, undissolved

solids/sediment, drain time, foam

expansion rate, spreading

coefficient - film formation (on

Cyclohexane) – film forming foams

only, alcohol burnback test (AR

foams only).

The results, and ‘pass’ or ‘fail’

conclusions, shall be given in a

report.

If the foam concentrate report does

not give a ‘pass’ i.e. fit for use, as a

result of its quality check tests, it

shall be

replaced immediately using foam

concentrate of the same type which

is passed fit for use

12MAdded

15) Foam

proportioning

accuracy test

A test of the proportioner and

associated fittings shall be carried

out. The test shall be carried out at

the maximum and minimum system

design flow rates. The accuracy of

foam proportioning shall be in

accordance with the tolerance given

in EN 13565-1. These tests should,

where possible, be carried out with

environmentally compatible foam

substitutes.

12MAdded

16) Discharge test A discharge test should be carried

out on each system to verify;

correct function of the system,

nozzles are free from blockage,

correct functioning of valves,

required discharge coverage is

achieved

12MAdded

17) Premix A check of the premixed foam

solutions properties shall be carried

out by competent and trained foam

laboratory personnel. If the

premixed foam solution report does

not give a ‘pass’ i.e. fit for use, as a

result of its quality check tests, it

shall be replaced immediately using

foam concentrate of the same type

which is passed fit for use

12MAdded

18) Concentrate Check the foam concentrate tanks

and components permanently in

contact with foam concentrate for

signs of external defects, e.g.

leakage, debris on seals.

12MAdded

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19) Vapour seals Inspect integrity of vapour seals on

tank foam pourers and burst discs

in subsurface systems

12MAdded

1. Alarms. Test all electrical detection and

alarm systems in accordance with

BS 5839.

3M 1) A) Pumps [not

foam concentrate

pumps]

Check the correct function of the

pumps and their drives (except

foam concentrate pumps). The test

run shall

last for a period in which the normal

operation conditions of the drive

like power consumption, oil and

cooling water temperature have

been reached. At the end of the

test run power consumption in the

case of electrical drives and

revolutions, oil and cooling water

temperature in the case of diesel

engine drives shall be measured.

Test run diesel engines to reach

operating temperatures (minimum

10 min).

1MLegislative

2. Foam

producing

equipment.

Inspect: for mechanical damage,

for corrosion, for blockage of air

inlets, clear as necessary, correct

manual function of all valves,

strainer and gauzes, proportioning

devices.

This may require temporary isolation

of the water main.

6M 1) B) Foam

concentration

pumps

Function test of automatic and

manual pump start devices of foam

concentrate pumps

1MLegislative

3. Control valves. Check for corrected manual and

automatic operation.

6M 2)Oil Levels Check of oil level of pumps,

compressors and diesel engines

1MLegislative

4. Pipework. Examine exposed pipework to

determine condition.

If visual indication of normally dry

pipework indicates questionable

strength due to corrosion or

mechanical damage, hydraulically

pressure test.

6M 3) Flow Pressure Check of the flow pressure in case

of systems feed directly from public

or factory mains

1MLegislative

5. Tanks for foam

concentrate and

solution.

Visually inspect without draining. Check any concentrate shipping

containers for evidence of

deterioration.

6M 4) Batteries Check of batteries concerning the

maintenance instructions given by

the battery manufacturer as well as

function of the battery charger

1MLegislative

6. Concentrate. Check condition. Correct any deterioration according

to the manufacturer's

recommendations.

12M 5)Diesel tanks Check of minimum fuel supply of

diesel engines

1MLegislative

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FIRE EXTINGUISHERS - GAS SUPPRESSION23-08 23-08 FIRE EXTINGUISHERS - GAS SUPPRESSION (Halon)

Note: As this type of equipment is pressurised it can be opened for inspection only after discharge.

This should be carried out after 10 years if the following annual maintenance has been carried out.

When removing parts from extinguishers, competent persons should ensure that they are clear of any

parts which might be ejected. Under no circumstances should any attempt be made to remove the

valves of high pressure extinguishers or cartridges under field conditions. Extreme caution should be

used when opening any extinguisher.

Such devices must only be maintained and tested by qualified engineers and in accordance with BS

5306-3:2009

Service of this type of extinguisher may only be carried out if the extinguisher meets the criteria of the

“critical uses” in Annex VII of EC Regulation 2037/2000

As this type of equipment is pressurised it can be opened for inspection only after discharge. This

should be carried out after 10 years if the following annual maintenance has been carried out.

Other


7) Extinguisher -

Overhaul

Empty the extinguisher and strip the

components down completely.

Reassemble and recharge the

extinguisher with new headcaps

and valves.

Selected halon alternative agents

have superseded halon usage in

fixed fire suppression system and

portable fire extinguisher

applications.

120MAdded

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FIRE EXTINGUISHERS - CARBON DIOXIDE23-09 23-09 FIRE EXTINGUISHERS - CARBON DIOXIDE

Note: For extinguishing kitchen cooking oil fires, Wet Chemical fire extinguishers (Class F) must be in

position.






5306-3:2009

Technical


6) Safety pin Remove the safety pin and check

that the operating lever is

undamaged and its movement is

unobstructed. Safety precautions

should be taken to avoid

inadvertent operation. Return the

safety pin or, where necessary, a

replacement pin to the extinguisher

12MAdded

7) Seals Ensure that all seals for the

discharge horn, the hose, the

nozzle and the valve body are in

place, as prescribed in the

extinguisher manufacturer’s

instructions.

12MAdded

8) Label Complete the details on the

maintenance label

12MAdded

9) Mounting

bracket/stand

Check any mounting bracket or

stand if accessible and rectify any

problems.

12MAdded

10) Report Write an inspection report advising

the responsible person of the state

of maintenance of the extinguisher

12MAdded

Page 203 of 614

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11)Overhaul

procedure every

10 years

a) Discharge the extinguisher.

Remove the swivel horn/hose

assembly, the valve and the valve

assembly, and remove the diptube

from the valve assembly. Destroy

the valve.

b) Pressure-test the body shell in

accordance with the test pressure

indicated on the body. Do not

overhaul the body if it is unmarked.

Permanently mark the body shell

with the retest date and the

identification of the organization

performing the test. (Attention is

drawn to the Carriage of Dangerous

Goods and Use of Transportable

Pressure Equipment Regulations

2007

c) Reassemble and recharge the

extinguisher with new

headcaps/valves

120MAdded

1. Extinguisher

body.

Examine for corrosion or damage. If replacement indicated report to

client.

12M 1) Safety Clip and

indicating devices

Check the safety clip and indicating

devices to determine whether the

extinguisher might have been

operated

12MLegislative

2. Contents. Weigh and check against records.

If loss greater than 10% recharge.

12M 2) External

examination

Examine the exterior for corrosion,

dents, gouges or damage that

could impair the safe operation of

the extinguisher paying particular

attention to any plastics headcap

for signs of degradation.

12MLegislative

3. Horn, hose

and valve

assembly.

Examine, clean and replace if not in

good condition.

12M 3) Weight check Weigh the extinguisher after

removal of the discharge horn/hose

assembly). Check the mass against

that

recorded when first put into service

or when last recharged and record

this on the maintenance label (In

the event of a loss of content of

more than 10%, discharge and

recharge

.

12MLegislative

4. Operating

mechanism (if

detachable).

Check operating mechanism and

discharge control (where fitted) for

free movement. Clean, rectify or

replace as necessary.

12M 4) Operating

instructions

Check the operating instructions for

correctness and legibility, ensuring

that the text is in English.

12MLegislative

5. Safety clip. Replace after maintenance activity

or renew wire seal as appropriate.

12M 5) Opening Open the extinguisher by

unscrewing the headcap. Remove

the gas cartridge.

12MLegislative

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FIRE EXTINGUISHERS - FOAM (Stored Pressure)23-10 23-10 FIRE EXTINGUISHERS - FOAM (Stored Pressure)






5306-3:2009

Added


1. Pressure

indicating device.

Check operation and pressure. If device inoperative or pressure is

below specified lower limit refer to

manufacturer's instructions. If no

device fitted use connection, if

provided, to verify pressure.


indicating devices




operated.

12MLegislative

2. Extinguisher

body.

Examine for corrosion or damage. If replacement indicated report to

client.

12M 2) Pressure –

indicating devices

Check the pressure-indicating

device where fitted. If it is not

operating freely or if the indicated

pressure is outside the specified

limits, refer to the extinguisher

manufacturer’s instructions to

ascertain the appropriate action to

be taken. Check that any dust

covers needed on

pressure-indicating or

pressure-relief devices are in place

and are of a size that does not

obscure the reading of the gauge.

Where a pressure-indicating device

is not fitted, verify, by means of the

connection provided for this

purpose, that the internal pressure

is correct. If it is not correct, refer to

the extinguisher manufacturer’s

instructions to ascertain the

appropriate action to be taken.

12MLegislative

3. Contents. Weigh and check against records. Report any loss.12M 3) External

examination







12MLegislative

4. Nozzle and

hose.

Examine and clean as necessary,

Check hose for wear or damage

and replace if necessary.




that






recharge

12MLegislative

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5. Operating

mechanism (if

detachable).





12M 5) Operating

instructions




12MLegislative



12M 6) Removable

operating

mechanism

Where the extinguisher is designed

to have the operating mechanism

removed without the discharge of

contents or loss of pressure,

remove and check the operating

mechanism and discharge control

(where fitted) for free movement.

Clean and lubricate the operating

mechanism, rectify any problems,

or replace with a new operating

mechanism as necessary.

12MLegislative

7. Internal

inspection.

Discharge contents, Examine for

corrosion, Refill if condition

satisfactory.

48M 7) Safety pin Remove the safety pin and check







replacement pin to the extinguisher.

12MLegislative

8) Seals The seals for the discharge horn,

the hose, the nozzle and the valve

body should be replaced with new

seals when these components are

removed from the extinguisher. If

the hose is fitted with a diaphragm,

this should always be replaced with

a new diaphragm.

Check the condition and fitness for

use of the discharge nozzle, horn

and hose, and ensure that the

nozzle, horn and hose, if fitted, are

not obstructed, cracked, worn, or

damaged. Replace with a new

nozzle, horn and/or hose if

necessary.

12MAdded

9) Reassembly Reassemble the extinguisher in

accordance with the instructions of

the extinguisher manufacturer.

Replace with new any safety clip

and indicating device designed to

show whether the extinguisher

might have been operated.

12MAdded


maintenance label

12MAdded

11) Mounting

bracket/stand



problems.

12MAdded

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12MAdded

Extended Service

procedures every

5 years

60MAdded

13) Prior to performing the test

discharge, the extinguisher should

be examined externally for any

obvious signs of damage to the

body or operating mechanism. If a

plastics headcap is coated in such

a way as to disguise degradation

(e.g. by painting), replace with a

new headcap before proceeding to

action 2. In the case of stored

pressure extinguishers, additional

safety precautions should be

observed.

60MAdded

14) Perform the test discharge on the

extinguisher.

60MAdded

15) Examine the body internally and in

detail for corrosion, dents, cuts,

gouges or lining damage. Pay

special attention to the welds.

Follow the extinguisher

manufacturer’s instructions where

there are any doubts about the

welds.

60MAdded

16) Examine and check all closures for

thread wear, damage and corrosion

as applicable.

60MAdded

17) Return the extinguisher to

operational condition. If the

extinguisher was fitted with a

plastics headcap, it should be fitted

with a new headcap, if this has not

already been fitted in action 13

(above). Reassemble and recharge

the extinguisher in accordance with

the extinguisher

manufacturer’s instructions

60MAdded

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FIRE EXTINGUISHERS - POWDER23-11 23-11 FIRE EXTINGUISHERS - POWDER (GAS CARTRIDGE)






5306-3:2009

Added


10) Gas cartridge Examine the gas cartridge

externally for corrosion or damage.

If the gas cartridge has suffered

mechanical damage or is corroded,

replace as recommended by the

extinguisher supplier. Weigh the

gas cartridge and check the mass

against that marked on the gas

cartridge. If the gas cartridge has

sustained a loss of content greater

than 10% (15% for cartridges with a

content mass of less than 30 g) of

the original content, withdraw it

from service and replace it with a

gas cartridge as recommended by


Check the date marked on the

cartridge

12MAdded








a new diaphragm.








necessary.

12MAdded

12) Body - powder Examine the interior with the aid of

an inspection light. Check for

corrosion and deterioration of lining,

if fitted.

0MAdded

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Change








12MAdded


maintenance label

12MAdded

15) Mounting

bracket/stand



problems.

12MAdded




12MAdded

Extended Service

procedures every

5 years

60MAdded













observed.

60MAdded


extinguisher.

60MAdded








welds.

60MAdded



as applicable.

60MAdded

Page 209 of 614

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the extinguisher


60MAdded

1. Contents. Weigh the extinguisher and if more

than 10% loss of powder, recharge.


indicating devices




operated.

12MLegislative

2. Condition of

powder.

Open container and examine

powder, if any evidence of lumps,

caking or foreign bodies, recharge.

If powder appears satisfactory,

agitate by inverting and shaking.

12M 2) External

examination







12MLegislative

3. Body. Examine internally and externally

for damage.




that






recharge.

12MLegislative

4. Gas cartridge. Examine for corrosion and damage.

Check weight.

Weight of contents is marked on

cartridge, replace if there is any loss

of weight. Cartridges over 10 years

old must be replaced.

12M 4) Operating

instructions




12MLegislative

5. Vent holes. Examine and clean.12M 5) Opening Open the extinguisher by


the gas cartridge.

12MLegislative

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6. Nozzle, hose

and internal

discharge tube.

Examine for any blockage, clean

rectify or replace as necessary.

12M 6) Powder charges Examine the powder of the

extinguisher. Agitate the powder by

inverting and shaking the

extinguisher, taking care to avoid

spillage. If there is any evidence of

caking, lumps, or foreign bodies, or

if the powder is not free flowing, or

if there is any doubt at all about the

condition of the powder, discard all

the powder and recharge. The use

of sieves or machines to remove

foreign bodies or caked or lumpy

material is not recommended since

this will involve considerable

exposure of the powder to

atmospheric humidity with a risk of

subsequent caking

12MLegislative

7. Operating

mechanism and

discharge control.

Check for free movement, clean

rectify or replace as necessary.

12M 7) Operating

mechanism and

air passages

Clean if necessary and pass air

through the air passages, paying

particular attention to the vent holes

(or other venting device) in the

headcap. Check that the strainer

(where fitted), internal discharge

tube and breather valve (where

fitted) are unobstructed.

Rectify any problems or replace

with a new tube or valve if

necessary. Renew gas-band, where

fitted.

Check the operating mechanism

and discharge control (where fitted)

for free movement. Rectify any

problems or replace with a new

operating mechanism or discharge

control as necessary. Protect

moving parts and threads against

corrosion with a lubricant as

recommended by the extinguisher

manufacturer.

12MLegislative

8. Washers and

diaphragms.

Examine and replace if necessary.12M 8) Removable

operating

mechanism











mechanism as necessary

12MLegislative

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12MLegislative

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FIRE EXTINGUISHERS - WATER - GAS CARTRIDGE23-12 23-12 FIRE EXTINGUISHERS - WATER - GAS CARTRIDGE

Note: If any soda acid extinguishers are found, the client must be informed that these must be

withdrawn from service.






5306-3:2009

Legislative


1. Body. Empty, examine for damage and

corrosion externally and internally.


indicating devices




operated.

12MLegislative

2. Contents. Check water level after refilling.12M 2) External

examination







12MLegislative

3. Gas cartridge. Examine externally for corrosion

and weigh and check against that

marked on the cartridge.




that recorded when first put into

service or when last recharged and

record this on the maintenance

label (In the event of a loss of

content of more than 10%,

discharge and recharge

12MLegislative

4. Vent holes. Examine and clean if necessary.12M 4) Operating

instructions




12MLegislative

5. Nozzle and

strainer and (if

fitted) internal

discharge tube

and breather

valve.

Examine and clean if necessary.12M 5) Opening Open the extinguisher by


the gas cartridge.

12MLegislative

6. Operating

mechanism and

discharge valve.

Check movement, clean, rectify

faults or replace.

12M 6) Water,

water-based, and

foam charges

Pour the original charge into a

clean container and, if it is to be

reused, check it in accordance with


instructions. Where the additive is

in a separate container, remove this

container and check it for leakage.

If the container has been

leaking, discard the container and

charge. Rinse out the body.

12MLegislative

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7. Sealing

washers and hose.

Examine and replace if not in good

condition.

12M 7) Operating

mechanism and

air passages

Clean if necessary and pass air

through the air passages, paying

particular attention to the vent holes

(or other venting device) in the

headcap. Check that the strainer

(where fitted), internal discharge

tube and breather valve (where

fitted) are unobstructed.

Rectify any problems or replace

with a new tube or valve if

necessary. Renew gas-band, where

fitted.

Check the operating mechanism

and discharge control (where fitted)

for free movement. Rectify any

problems or replace with a new

operating mechanism or discharge

control as necessary. Protect

moving parts and threads against

corrosion with a lubricant as


manufacturer

0MLegislative

8. Recharge. Fill to correct level. Note any special needs, e.g.

anti-freeze or corrosion inhibitor.

12M 8) Removable

operating

mechanism












Note any special precautions, e.g.

anti-freeze or corrosion inhibitor.

12MLegislative











12MLegislative

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10) Gas cartridge Examine the gas cartridge

externally for corrosion or damage.

If the gas cartridge has suffered

mechanical damage or is corroded,

replace as recommended by the

extinguisher supplier. Weigh the

gas cartridge and check the mass

against that marked on the gas

cartridge. If the gas cartridge has

sustained a loss of content greater

than 10% (15% for cartridges with a

content mass of less

than 30 g) of the original content,

withdraw it from service and replace

it with a gas cartridge as


manufacturer. Check the date

marked on the cartridge

12MAdded








a new diaphragm.








necessary.

12MAdded

12) Body: water,

water-based

and foam

Examine the interior with the aid of

an inspection light. Check for

corrosion or lining deterioration.

Check separate containers for

additives and replace if they are

leaking or damaged

12MAdded

13) Water and

water-based

(including foam)

charges

Return the original charge to the

extinguisher, or replace with new

charge according the instructions of

the extinguisher manufacturer

12MAdded








12MAdded


maintenance label

12MAdded

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16) Mounting

bracket/stand



problems.

12MAdded




12MAdded

Extended Service

procedures every

5 years

60MAdded













observed.

60MAdded


extinguisher.

60MAdded








welds.

60MAdded



as applicable.

60MAdded










instructions

60MAdded

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Change

FIRE EXTINGUISHERS - WATER STORED PRESSURE23-13 23-13 FIRE EXTINGUISHERS - WATER STORED PRESSURE






5306-3:2009

Added









12MAdded


maintenance label

12MAdded

11) Mounting

bracket/stand



problems.

12MAdded




12MAdded

Extended Service

procedures every

5 years

60MAdded













observed.

60MAdded


extinguisher.

60MAdded








welds.

60MAdded

Page 217 of 614

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Reason For

Change



as applicable.

60MAdded










instructions

60MAdded

1. Body. Examine externally for corrosion

and damage.


indicating devices




operated.

12MLegislative

2. Contents. Weigh and check against original

weight when put into service.

12M 2)

Pressure-indicatin

g devices

Check the pressure-indicating

device where fitted. If it is not

operating freely or if the indicated

pressure is outside the specified

limits, refer to the extinguisher

manufacturer’s instructions to

ascertain the appropriate action to

be taken. Check that any dust

covers needed on

pressure-indicating or

pressure-relief devices are in place

and are of a size that does not

obscure the reading of the gauge.

Where a pressure-indicating device

is not fitted, verify, by means of the

connection provided for this

purpose, that the internal pressure

is correct. If it is not correct, refer to


instructions to ascertain the

appropriate action to be taken.

12MLegislative

3. Pressure

indicator on stored

pressure

equipment.

Check operation, if less than

specified refer to manufacturer's

instructions.

Where device not fitted, check by

means of connector provided.

12M 3) External

examination







12MLegislative

4. Contents. Weigh and check against records. Report any loss.12M 4) Weight check Weigh the extinguisher after



that recorded when first put into

service or when last recharged and

record this on the maintenance

label (In the event of a loss of

content of more than 10%,

discharge and recharge

.

12MLegislative

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5. Nozzle and

hose.

Examine and clean as necessary,

Check hose for wear or damage


12M 5) Operating

instructions




12MLegislative

6. Operating

mechanism (if

detachable).





12M 6) Removable

operating

mechanism












12MLegislative











12MLegislative

8. Internal

inspection.

Discharge contents, Examine for

corrosion, Refill if condition

satisfactory.

48M 8) Seals The seals for the discharge horn,







a new diaphragm.








necessary

.

12MLegislative

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SPRINKLER SYSTEMS23-14 23-14 SPRINKLER SYSTEMS

Introduction

Automatic sprinkler systems must be maintained in accordance with BS EN 12845:2004 and the LPC

publication - TB203: 2004.

An automatic sprinkler system is designed to detect a fire and extinguish it with water in its early

stages or hold the fire in check so that extinguishment can be completed by other means.

The sprinklers operate at predetermined temperatures to discharge water over the affected part of the

area below. The flow of water through the alarm valve initiates a fire alarm. The operating temperature

is generally selected to suit ambient temperature conditions.

Under BS EN 12845:2004 there are planned maintenance tasks for 3 and 10 year frequencies these

are not covered in these instruction sets.

Introduction

Automatic sprinkler systems must be maintained in accordance with BS EN 12845:2004 + A2:2009

incorporating corrigendum August 2009 Fixed firefighting systems- automatic sprinkler systems-

Design, Installation and maintenance and the LPC publication - TB203: 2004.

An automatic sprinkler system is designed to detect a fire and extinguish it with water in its early

stages or hold the fire in check so that extinguishment can be completed by other means.

The sprinklers operate at predetermined temperatures to discharge water over the affected part of the

area below. The flow of water through the alarm valve initiates a fire alarm. The operating temperature

is generally selected to suit ambient temperature conditions.

Under BS EN 12845:2004 there are planned maintenance tasks for 3 and 10 year frequencies these

are not covered in these instruction sets.

Only the user should give permission for a sprinkler installation or zone to be shut down for any

reason other than an emergency.

Before a system is wholly or partly shut down every part of the premises should be checked to ensure

that there is no indication of fire.

Where premises are subdivided into separate occupancies constituting buildings in communication or

at risk, protected by common sprinkler systems or installations, all occupiers should also be advised

that the water is to be turned off.

Particular attention should be given to situations where installation pipework passes through walls or

ceilings where these may feed sprinklers in areas needing special consideration

Technical


SERVICE &

MAINTENANCE

The effect of any changes of

structure, occupancy, storage

configuration, heating, lighting or

equipment etc. of a building on

hazard classification or installation

design shall be identified in order

that the appropriate modifications

may be carried out.

Added

1. System Checks The following must be checked and

recorded: all water and air pressure

gauge readings on installation,

trunk mains and pressure tanks;

The pressure in the pipework in dry,

alternate and pre-action installations

should not fall at a rate of more than

1.0 bar per week. All results must be

recorded in Fire Alarm log book

1W 1. System

Checks

The following must be checked and

recorded (in sprinkler Log Book): all

water and air pressure gauge

readings on installation, trunk

mains and pressure tanks;

The pressure in the pipework in dry,

alternate and pre-action installations

should not fall at a rate of more than

1.0 bar per week. All results must be

recorded in Sprinkler log book

1WLegislative

2. System Checks All water levels in elevated private

reservoirs, rivers, canals, lakes,

water storage tanks (including

pump priming water tanks and

pressure tanks);

All results must be recorded in Fire

Alarm log book

1W 2. System

Checks

All water levels in elevated private

reservoirs, rivers, canals, lakes,

water storage tanks (including

pump priming water tanks and

pressure tanks);

All results must be recorded in

Sprinkler log book

1WLegislative

3. System Checks That all main stop valves are in the

correct position.


Alarm log book

1W 3. System

Checks

That all main stop valves are in the

correct position.


Sprinkler log book

1WLegislative

Page 220 of 614

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4. Water motor

alarm test

Each water motor alarm shall be

sounded for no less than 30 s.

Also Known as Mechanical Bell test.


Alarm log book

1W 4. Water motor

alarm test

Each water motor alarm shall be

sounded for no less than 30

seconds.

Also Known as Mechanical Bell test.


Sprinkler log book

1WLegislative

5. Automatic

pump starting

Electric Motor

Tests automatic pumps and include

the following; a) water pressure on

the starting device shall be

reduced, to simulate the condition

of automatic starting; b) when the

pump starts, the starting pressure

shall be checked and recorded;


Alarm log book

1W 5a. Automatic

pump starting test

-Electric Motor

Test automatic pumps and include

the following; a) water pressure on

the starting device shall be

reduced, to simulate the condition

of automatic starting; b) when the

pump starts, the starting pressure

shall be checked and recorded;


Sprinkler log book

1WLegislative

5. Automatic

pump starting

Diesel

Tests automatic pumps and include

the following; a) fuel and engine

lubricating oil levels in diesel

engines. b) water pressure on the

starting device shall be reduced, to

simulate the condition of automatic

starting; c) when the pump starts,

the starting pressure shall be

checked and recorded; d) the oil

pressure on diesel pumps shall be

checked, as well as the flow of

cooling water through open circuit

cooling systems.


Alarm log book

1W 5b. Automatic

pump starting test

- Diesel

Test automatic pumps and include

the following; a) fuel and engine

lubricating oil levels in diesel

engines. b) water pressure on the

starting device shall be reduced, to

simulate the condition of automatic

starting; c) when the pump starts,

the starting pressure shall be

checked and recorded; d) the oil

pressure on diesel pumps shall be

checked, as well as the flow of

cooling water through open circuit

cooling systems.


Sprinkler log book

1WLegislative

6. Diesel engine

restarting test

Immediately after the pump start

test diesel engines shall be tested

as follows: a) the engine shall be

run for 20 min, or for the time

recommended by the supplier. The

engine shall then be stopped and

immediately restarted using the

manual start test button; b) The

water level in the primary circuit of

closed circuit cooling systems shall

be checked. Oil pressure (where

gauges are fitted), engine

temperatures and coolant flow shall

be monitored throughout the test.

Oil hoses shall be checked and a

general inspection made for

leakage of fuel, coolant or exhaust

fumes.


Alarm log book

1W 6. Diesel engine

restarting test

Immediately after the pump start

test diesel engines shall be tested

as follows: a) the engine shall be

run for 20 min, or for the time

recommended by the supplier. The

engine shall then be stopped and

immediately restarted using the

manual start test button; b) The

water level in the primary circuit of

closed circuit cooling systems shall

be checked. Oil pressure (where

gauges are fitted), engine

temperatures and coolant flow shall

be monitored throughout the test.

Oil hoses shall be checked and a

general inspection made for

leakage of fuel, coolant or exhaust

fumes.


Sprinkler log book

1WLegislative

7. Trace heating

and localized

heating systems

Heating systems to prevent

freezing in the sprinkler system

shall be checked for correct

function.

1W 7. Trace heating

and localised

heating systems

Heating systems to prevent freezing

in the sprinkler system shall be

checked for correct function.

1WOther

Page 221 of 614

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1. System

Batteries

The electrolyte level and density of

all lead acid cells (including diesel

engine starter batteries and those

for control panel power supplies)

shall be checked. If the density is

low the battery charger shall be

checked and, if this is working

normally, the battery or batteries

affected shall be replaced.

For the risks above refer to the

COSHH Regulations -

www.hse.gov.uk


Alarm log book

1M 1. System

Batteries

The electrolyte level and density of

all lead acid cells (including diesel

engine starter batteries and those

for control panel power supplies)

shall be checked. If the density is

low the battery charger shall be

checked and, if this is working

normally, the battery or batteries

affected shall be replaced.

For the risks above refer to the

COSHH Regulations -

www.hse.gov.uk


Sprinkler log book

1MLegislative

2. Sprinklers,

multiple controls

and sprayers

Sprinklers, multiple controls and

sprayers affected by deposits (other

than paint) shall be carefully

cleaned. Painted or distorted

sprinkler heads, multiple controls or

sprayers shall be replaced. Any

petroleum jelly coatings shall be

checked. Where necessary the

existing coatings shall be removed

and the sprinklers, multiple controls

or sprayers shall be coated twice

with petroleum jelly (in the case of

glass bulb sprinklers to the sprinkler

body and yoke only). Particular

attention shall be paid to sprinklers

in spray booths, where more

frequent cleaning and/or protective

measures may be necessary.


Alarm log book

3M 1. Sprinklers,

multiple controls

and sprayers

Sprinklers, multiple controls and

sprayers affected by deposits (other

than paint) shall be carefully

cleaned. Painted or distorted

sprinkler heads, multiple controls or

sprayers shall be replaced. Any

petroleum jelly coatings shall be

checked. Where necessary the

existing coatings shall be removed

and the sprinklers, multiple controls

or sprayers shall be coated twice

with petroleum jelly (in the case of

glass bulb sprinklers to the sprinkler

body and yoke only). Particular

attention shall be paid to sprinklers

in spray booths, where more

frequent cleaning and/or protective

measures may be necessary.


Sprinkler log book

3MLegislative

3. Pipework and

pipe supports

Pipework and hangers shall be

checked for corrosion and painted

as necessary. Bitumen-based paint

on pipework, including the threaded

ends of galvanized pipework and

hangers, shall be renewed as

necessary. Tape wrapping on pipes

shall be repaired as necessary. The

pipework shall be checked for

electrical earthing connections.

Sprinkler pipework shall not be

used for earthing electrical

equipment and any earthing

connections from electrical

equipment shall be removed and

alternative arrangements made.


Alarm log book

3M 2. Pipework and

pipe supports

Pipework and hangers shall be

checked for corrosion and painted

as necessary. Bitumen-based paint

on pipework, including the threaded

ends of galvanized pipework and

hangers, shall be renewed as

necessary. Tape wrapping on pipes

shall be repaired as necessary. The

pipework shall be checked for

electrical earthing connections.

Sprinkler pipework shall not be

used for earthing electrical

equipment and any earthing

connections from electrical

equipment shall be removed and

alternative arrangements made.


Sprinkler log book

Bitumen-based paint may need

renewal at intervals varying from 1

to 5 years according to the severity

of the conditions.

3MOther

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4. Water supplies

and their alarms

Each water supply shall be tested

with each control valve set in the

system. The pump(s), if fitted, in

the supply shall start automatically

and the supply pressure at the

appropriate flow rate shall be no

less than the appropriate value


Alarm log book

3M 3. Water supplies

and their alarms

Each water supply shall be tested

with each control valve set in the

system. The pump(s), if fitted, in the

supply shall start automatically and

the supply pressure at the

appropriate flow rate shall be no

less than the appropriate value in

accordance with clause 10 PUMPS

[BS EN 12845:2004+A2:2009

incorporating corrigendum August

2009] and recognising any changes

required due to any changes of

structure, occupancy, storage

configuration, heating, lighting or

equipment etc. of a building on

hazard classification or installation

design


Sprinkler log book

3MLegislative

5. Electrical

supplies

Any secondary electrical supplies

from diesel generators shall be

checked for satisfactory operation.


Alarm log book

3M 4. Electrical

supplies

Any secondary electrical supplies

from diesel generators shall be

checked for satisfactory operation.


Sprinkler log book

3MLegislative

6. Stop valves All stop valves controlling the flow

of water to sprinklers shall be

operated to ensure that they are in

working order and securely

refastened in the correct mode.

This shall include the stop valves

on all water supplies, at the alarm

valve(s) and all zone or other

subsidiary stop valves.


Alarm log book

3M 5. Stop valves All stop valves controlling the flow

of water to sprinklers shall be

operated to ensure that they are in

working order and securely

refastened in the correct mode.

This shall include the stop valves

on all water supplies, at the alarm

valve(s) and all zone or other

subsidiary stop valves.


Sprinkler log book

3MLegislative

7. Flow switches Flow switches shall be checked for

correct function.


Alarm log book

3M 6. Flow switches Flow switches shall be checked for

correct function.


Sprinkler log book

3MLegislative

8. Replacement The number and condition of

replacement parts held as spare

shall be checked.


Alarm log book

3M 7. Replacement The number and condition of

replacement parts held as spare

shall be checked.


Sprinkler log book

3MLegislative

1. Dry alarm

valves

The moving parts of dry alarm

valves, any accelerators and

exhausters, in dry pipe installations

and subsidiary extensions shall be

exercised in accordance with the

supplier’s instructions.

NOTE Alternate installations need

not be tested in this way since they

are exercised twice a year as a

result of the changeover from wet to

dry operation and back.

6M 1. Dry alarm

valves

The moving parts of dry alarm

valves, any accelerators and

exhausters, in dry pipe installations

and subsidiary extensions shall be

exercised in accordance with the

supplier’s instructions.

Alternate installations need not be

tested in this way since they are

exercised twice a year as a result of

the changeover from wet to dry

operation and back.


Sprinkler log book

6MLegislative

2. Fire brigade

and remote central

station alarm

Where fitted central station

monitoring alarms must be tested.

Activate the alarm with central

station on line to test connection. All

results must be recorded in Fire

Alarm log book

6M 2. Fire brigade

and remote central

station alarm

Where fitted central station

monitoring alarms must be tested.

Activate the alarm with central

station on line to test connection. All

results must be recorded in

Sprinkler log book

6MOther

Page 223 of 614

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3. Automatic

pump flow test

Each water supply pump in the

installation shall be tested at the full

load condition (by means of the test

line connection coupled to the

pump delivery branch downstream

of the pump outlet non-return valve)

and shall give the pressure/flow

values stated on the nameplate.

Appropriate allowances shall be

made for pressure losses in the

supply pipe and valves between the

source and each control valve set.


Alarm log book

12M 1. Automatic

pump flow test

Each water supply pump in the

installation shall be tested at the full

load condition (by means of the test

line connection coupled to the

pump delivery branch downstream

of the pump outlet non-return valve)

and shall give the pressure/flow

values stated on the nameplate.

Appropriate allowances shall be

made for pressure losses in the

supply pipe and valves between the

source and each control valve set.


Sprinkler log book

12Mtechnical

4. Diesel engine

failed-to-start test

The failed-to-start alarm shall be

tested

Immediately after this test the

engine shall be started using the

manual starting system. All

results must be recorded in Fire

Alarm log book

12M 2. Diesel engine

failed-to-start test

The failed-to-start alarm shall be

tested

Immediately after this test the

engine shall be started using the

manual starting system. All results

must be recorded in Sprinkler log

book

12Mtechnical

5. Float valves on

water storage

tanks

Float valves on water storage tanks

shall be checked to ensure they

function correctly.


Alarm log book

12M 3. Float valves on

water storage

tanks

Float valves on water storage tanks

shall be checked to ensure they

function correctly.


Sprinkler log book

12Mtechnical

6. Pump suction

chambers and

strainers

Pump suction strainers and settling

chamber and their screens shall be

inspected at least annually and

cleaned as necessary.


Alarm log book

12M 4. Pump suction

chambers and

strainers

Pump suction strainers and settling

chamber and their screens shall be

inspected at least annually and

cleaned as necessary.


Sprinkler log book

12Mtechnical

Page 224 of 614

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23-15 GAS DETECTION

Prior to carrying out any work ensure regulations and site procedures are followed. Never attempt to

open the detector or junction box when flammable gas is present. Ensure that the associated control

panel is inhibited so as to prevent false alarms.

Added


1. Gas detection Check function and operation of all

automatic sensors, ensure for

correct operation/shut-down of

plant and/or any ancillary control

device. Ensure all devices are

returned to their correct settings.

Site practices will dictate the

frequency with which detectors are

tested.

3MAdded

2. Gas Test Carry out gas test in accordance

with the manufaturers guidelines.

6MAdded

3. Calibration Detector should be recalibrated in

accordance with the manufaturers

guidelines.

12MAdded

4. Dust filter if

fitted

Test to ensure filter has not become

blocked. Frequency depends on

local risk assessment and relating

to the ammount of dust in the

atmpshere where the the detector

is installed.

Frequency depends on local risk

assessment and relating to the

ammount of dust in the atmpshere

where the the detector is installed.

Added

Page 225 of 614

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23-16 KITCHEN HOOD FIRE SUPPRESSION

There are three main types of suppression system;

1) Carbon dioxide

2) Chemical both liquid and dry

3) Water

Chemical fire suppressant ia an alkaline compound and all due care and attention should be taken

when handling such a substance.

In addition to the specialist maintenance tasks there should be an operational task carried out by the

client or kitchen head to visually check the whole system on a regular basis.

All systems differ from type and manufacturer to manufacturer. It is essential that the maintenance is

carried out in full accordance with those manufacturers instruction and by a trained specialist who has

undergone the instructions necessary to perform the maintenance and recharge service on the actual

type of equipment in place.

Added


1). Visual

examination

The extinguishing system is in its

proper location

• Manual actuators are

unobstructed

• Tamper indicators and seals are

intact

• The maintenance tag or certificate

is in place

• There is no obvious physical

damage

• Pressure gauges, if provided, are

in operable range

• The blowoff caps are intact and

undamaged

• The hood, duct and protected

cooking appliances have not been

replaced, modified or replaced.

If any deficiencies are found,

appropriate corrective action shall

be taken immediately and the client

informed. A written record of these

findings should be kept.

Each system shall have a tag or

label sucurely attached, indicating

the month and year the

maintenance is performed and

identifying the person performing

the service. Only the current tag or

label shall remain in place.

1MAdded

2). System check Check to see that the hazard has

not changed.

Check of all actuation components,

including remote manual pull

stations, mechanical or electrical

devices, detectors, actuators and

fire-actuated dampers, agent

containers, pipework, hoses and

the liquid level of all non

pressurised wet chemical

containers to ensure that they are

in operable condition.

6MAdded

3). Fire alarm

interconnect

switches

Carry out a visual inspection of fire

alarm interconnect switches.

6MAdded

Page 226 of 614

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4). System test All chemical systems shall be

tested and includes the operation of

the detection system signals and

releasing devices, including manual

stations and other associated

equipment. A discharge of the wet

chemical normally is not part of the

test.

Where the maintenance of the

system reveals defective parts that

could cause an impairment or failure

of proper operation of the system,

the affected parts shall be replaced

or repaired in accordance with the

manufacturers recommendations.

6MAdded

5). Fusible links

and automatic

sprinkler heads.

Fusible links and automatic

sprinkler heads are required to be

replaced at least annually, but may

have to be replaced more

frequently if a visual inspection

shows that to be necessary. By

exception, bulb-type sprinklers or

spray nozzles do not need to be

replaced if an annual examination

shows no buildup of grease or other

material on the sprinkler or spray

nozzles.

The replaced fusible links / heads

shall be destroyed when removed.

The year of manufacture and the

date of installation of the fixed

temperature-sensing element shall

be marked on the system inspection

tag. The tag shall be signed or

initialed by the specialist service

provider.

12MAdded

6). Fire alarm

interconnect

switches

Fire alarm interconnect switches

are required to be tested annually

by mechanically or electrically

operating the switch to verify receipt

of a signal at the fire alarm control

panel. This testing should be

performed as part of the annual test

conducted of the building fire alarm

system.

12MAdded

7). Major overhaul. Major system overhaul [maximum

time this should be carried out].

36MAdded

8). Hydrostatic

testing

Wet chemical containers, auxiliary

pressure containers and hose

assemblies shall be subject to a

hydrostatic pressure test at

intervals not exceeding 12 years.

144MAdded

Page 227 of 614

FLUES

Page 228 of 614

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FLUES (all combustible fuels)24-01 24-01 FLUES (all combustible fuels)

These notes should be read in conjunction with relevant sections BOILERS GAS, OIL SOLID FUEL –

burning appliances. Only GAS SAFE registered contractors are permitted to work on GAS

flues. Ensure that flues conform to relevant guidance and BS/EN and boiler manufacturers’

recommendation. External dampers/economisers can infringe manufacturer’s guarantees and also

HASAWA.

It is essential to ensure that any discharge point does not endanger others, these must be proved

safe.

These notes should be read in conjunction with relevant sections Boilers - Heat generators SFG 05-01

to 05-33 . Only GAS SAFE registered service providers are permitted to work on flues. Ensure that

flues conform to relevant guidance and BS/EN and boiler manufacturers’ recommendation. External

dampers/economisers can infringe manufacturer’s guarantees and also HASAWA (www.hse.gov.uk).

Soot can be found in flues burning oil and coal. Soot is classified as a Hazard and disposed of on

accordance with the Hazard Waste and COSHH Regulations.

It is essential to ensure that any discharge point does not endanger others, these must be proved

safe.

Technical


3. Flue terminals. Where possible, check flue

terminals at roof level.

It is very important that flue

terminals must be undamaged and

free from any obstruction.

12M 3. Flue terminals. Where possible, check flue

terminals at roof level.

It is very important that flue

terminals must be undamaged and

free from any obstruction.

12MOther

Page 229 of 614

FOUNTAINS

Page 230 of 614

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FOUNTAINS - ORNAMENTAL25-01 25-01 FOUNTAINS OUTDOOR - ORNAMENTAL

Notes: Latest ACOP L8,2001 - Precautions in respect of Legionellosis and legionnaires' disease

apply.

Precautions in respect of Legionellosis and legionnaires` disease apply.



system, limitations detailed in ACOP L8,2001 must be identified and assessed for legionellosis risk.

Once a risk has been identified and assessed a scheme must be prepared for preventing or

controlling it, precautions implemented and managed records kept. The L8 has a special legal status,

Part 1 being regulatory and Part 2 guidance.

Technical


2. Pumps. Check for gland leakage and


More detailed information on the

maintenance see relevant section of

PUMPS.

12M 2. Pumps. Check for gland leakage and




Pumps SFG 45-01

12MOther

5. Water

treatment plant.

Note: does not

apply when fish

present.

See WATER TREATMENT. Presence of fish will required special

consideration.

12M 5. Water

treatment plant.

This does not

apply when fish

present.

See Water treatment SFG 65-01 Presence of fish will required special

consideration.

12MOther

6. Automatic

water make-up, a)

float operated (ball

valve),

See STORAGE TANKS WATER12M 6. Automatic

water make-up, a)


valve),

Check operation, water level and

shut off. Replace washer if

necessary. Check float for leakage

and security

Also See Storage tanks water SFG

56-01

12MTechnical

b) solenoid

operated.

See - VALVES.12M b) solenoid

operated.

Operate and check for correct

linear travel. Check for solenoid

noise i.e. buzzing.b) Check that

valve is not letting by excessively.

c) Inspect for gland leakage, refer

to manufacturer`s maintenance

instructions.d) Inspect for external

deterioration.

Also See - Valves- automatic SFG

65-05

12MTechnical

7. Underwater

lighting.

See - LIGHTING .12M 7. Underwater

lighting.

Clean and check:For physical

damage. Signs of water ingress or

condensation, check seals and

report to client. Check integrity of

electrical wiring and earth

continuity. Check for failed or

blackened tubes or lamps. Replace

as necessary

Also See - Lighting SFG 36-01

12MTechnical

Page 231 of 614

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25-02 FOUNTAINS INDOOR - ORNAMENTAL

Precautions in respect of Legionellosis and legionnaires` disease apply.






Part 1 being regulatory and Part 2 guidance.

The frequency of the tasks are to be set in relation to the condition of the fountain and in line with the

description with L8.

Added


1. Spray heads

and jets.

Clean and check spray pattern. Frequency will depend upon

location and use and should be

agreed with client.

3MAdded

2. Pumps. Check for gland leakage and




Pumps SFG 45-01

12MAdded

3. Filters. Check condition and clean as

necessary.

Frequency will depend upon

location and use and should be

agreed with client.

12MAdded

4. Containment

area, e.g. tanking.

Check for cracks and signs of

leakage. Report to client if

remedial work is required.

Failure of the waterproof lining or

membrane is the most likely source

of leakage. Frost damage to

concrete is another cause.

12MAdded

5. Water

treatment plant.

This does not

apply when fish

present.

See Water treatment SFG 65-01 Presence of fish will required special

consideration.

12MAdded

6. Automatic

water make-up, a)


valve),




and security

Also See Storage tanks water SFG

56-01

12MAdded

b) solenoid

operated.


linear travel. Check for solenoid

noise i.e. buzzing.b) Check that

valve is not letting by excessively.

c) Inspect for gland leakage, refer

to manufacturer`s maintenance

instructions.d) Inspect for external

deterioration.

Also See - Valves- automatic SFG

65-05

12MAdded

Page 232 of 614

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7. Underwater

lighting.

Clean and check:For physical


condensation, check seals and

report to client. Check integrity of

electrical wiring and earth

continuity. Check for failed or

blackened tubes or lamps. Replace

as necessary

Also See - Lighting SFG 36-01

12MAdded

Page 233 of 614

GRILLES AND DIFFUSERS

Page 234 of 614

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GRILLES AND DIFFUSERS26-01 26-01 GRILLES AND DIFFUSERS

Where possible these should be removed for cleaning. Washing to remove grease and staining may

be required.

Diffuser/grille locations and orientation should be marked or recorded if they are to be taken away for

washing, so that they can be returned to the correct location. Opposed blade dampers should have

the ‘as found’ setting marked to aid resetting.

Certain grille and diffuser arrangements may be installed such that they cannot be practicably

removed for cleaning, e.g. linear diffusers or those trapped by partition walls. Insitu cleaning by air line

and extraction to capture dislodged deposits may be used.

Diffusers may have plenum boxes, possibly containing dampers behind them, which also require

cleaning. Access will be required to permit cleaning or air jetting and extraction methods.

Added


a) external Examine, check mountings and

clean.

Leaves can be particular nuisance

and one examination should be in

late Autumn.

6M a) external Examine, check mountings and

clean. Replace if holed.

Where significant bird contamination

or mould problems are encountered

a preliminary disinfection before

starting work may be required and

appropriate protection provided for

cleaning operatives.

6MOther

b) internal Examine, check fitting and clean. If removed care should be taken not

to disturb valve and other equipment

settings behind the grille.

12M b) internal Examine, check fitting and clean.12MOther

2. Diffusers. Examine, check fitting and clean. If removed care should be taken not

to disturb valve and other equipment

settings behind the diffuser.

12M 2. Diffusers. Examine, check fitting and clean.12MOther

Page 235 of 614

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LOUVRES, BIRD AND INSECT SCREENS26-02 26-02 LOUVRES, BIRD AND INSECT SCREENS


1. Louvres. Clean and remove any debris,

check for damage.

6M 1. Louvers. Clean and remove any debris,

check for damage.

Where significant bird contamination

or mould problems are encountered

a preliminary disinfection before

starting work may be required and

appropriate protection provided for

cleaning operatives.

6MOther

Page 236 of 614

HAZARDOUS AREA (ELECTRICS)

Page 237 of 614

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It is essential that any maintenance work in hazardous areas is only carried out by specialist

personnel. Extreme care should be taken when carrying out such maintenance and it is very important

that equipment such as electric motors, flameproof switchgear and lighting should be returned to

service in a safe condition.

Hazardous areas are classified into three zones.

Zone 0 In which an explosive gas-air mixture is continuously present, or for long periods.

Zone 1 In which an explosive gas-air mixture is likely to occur in normal operation.

Zone 2 In which an explosive gas-air mixture is not likely to occur in normal operation and if it occurs

will only exist for a short time.

The above classification does not apply to dusts and an area classification for dusts is being

prepared.

BS EN 60079 - 2009 is the latest publication dealing with the classification of hazardous areas whilst

CP 1003 Part I which covers choice, installation and maintenance of flameproof and intrinsically safe

equipment is being slowly withdrawn although it is still in use.

During maintenance in such areas the following points should be noted:-

a) all flameproof lighting fittings should be examined for incipient cracks,

b) when equipment is returned to service the gap for a particular joint should not exceed that specified

by the manufacturers,

c) damage to machined flanges must be avoided,

d) joints should be wiped clean and non-setting grease or BASEEFA/HSE(M) approved compound as

appropriate applied. Excess grease is not a substitute for containing the flamepath gap.

e) Cover bolts are in accordance with the standard requirements of specific minimum strength and

should not be replaced by screws other than those obtained from the manufacturer for that

specific purpose.

It is essential that any maintenance work in hazardous areas is only carried out by specialist

personnel. Extreme care should be taken when carrying out such maintenance and it is very important

that equipment such as electric motors, flameproof switchgear and lighting should be returned to

service in a safe condition.

This task is intended to be applied where there can be a risk due to the presence of explosive gas or

dust mixtures with air or combustible dust layers under normal atmospheric conditions. It does not

apply to

• underground mining areas,

• areas where a risk can arise due to the presence of hybrid mixtures,

• dusts of explosives that do not require atmospheric oxygen for combustion,

• pyrophoric substances.

Hazardous areas are classified into three zones.

GAS

Zone 0 an explosive gas atmosphere is present continuously or for long periods or frequently.

Zone 1 an explosive gas atmosphere is likely to occur in normal operation occasionally.

Zone 2 an explosive atmosphere is not likely to occur in normal operation but, if it does occur, will

persist for a short period only.

DUST

Zone 20 A place in which an explosive dust atmosphere, in the form of a cloud of dust in air, is

present continuously or for long periods or frequently.

Zone 21 A place in which an explosive dust atmosphere, in the form of a cloud of dust in air, is likely to

occur in normal operation occasionally.

Zone 22 A place in which an explosive dust atmosphere, in the form of a cloud of dust in air, is not

likely to occur in normal operation but, if it does occur, will persist for a short period only.

During maintenance in such areas the following points should be noted:-

a) all flameproof lighting fittings should be examined for incipient cracks,

b) when equipment is returned to service the gap for a particular joint should not exceed that specified

by the manufacturers,

c) damage to machined flanges must be avoided,

d) joints should be wiped clean and non-setting grease or BASEEFA/HSE(M) approved compound as

appropriate applied. Excess grease is not a substitute for containing the flamepath gap.

e) Cover bolts are in accordance with the standard requirements of specific minimum strength and

should not be replaced by screws other than those obtained from the manufacturer for that specific

purpose.


SFG 14-01 introductory notes, very carefully and follow all the safety procedures

Other

Page 238 of 614

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Hazardous areas - FLAME PROOF EQUIPMENT27-02 27-02 Hazardous areas - FLAME PROOF EQUIPMENT

The results of inspections, checks and tests must be recorded and compared with previous entries,

any significant changes must be investigated and specifically reported upon to the client.

Before commencing any maintenance work on Flame proof equipment, read Hazardous area

(electrics) introductory procedures SFG 27-01 very carefully and follow all the safety procedures.

Replacement parts shall be in accordance with the safety documentation. Alterations to equipment

shall not be carried out without appropriate authorisation where they adversely affect the safety of the

equipment as stated in the safety documentation. Repairs and reclamation of equipment shall be

carried out in accordance with IEC 60079-19.

Definition - flameproof enclosure “d” enclosure in which the parts which can ignite an explosive gas

atmosphere are placed and which can withstand the pressure developed during an internal explosion

of an explosive mixture, and which prevents the transmission of the explosion to the explosive gas

atmosphere surrounding the enclosure

Other

Page 239 of 614

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Hazardous areas - LIGHTING27-03 27-03 Hazardous areas - LIGHTING






carried out in accordance with IEC 60079-19.

Added


1. Integrity. Check installation for mechanical

damage.

6M 1. Integrity. Check installation for mechanical

damage.

The etching, painting or screening of

light transmitting parts or the

incorrect positioning of the

luminaires may lead to excessive

temperatures

6MTechnical

3. Lamp. Replace on a planned basis as

appropriate.

Maintenance contract should be

specific with regard to the

responsibility for the provision and

replacement of lamps and also for

the disposal of spent lamps, as per

statutory regulations.

6M 3. Lamp. Replace on a planned basis as

appropriate.

When replacing lamps the correct

rating and type ONLY should be

used, or excessive temperatures

may result. Maintenance contract

should be specific with regard to the

responsibility for the provision and

replacement of lamps and also for

the disposal of spent lamps, as per

statutory regulations.

6MLegislative

4. Cable and

conduit entries.

Check condition of sealing rings

etc.

Note: any cable gland, stopping

gland or plug, reducer or adapter

must be BASEEFA approved for use

with the apparatus.

6M 4. Cable and

conduit entries.

Check condition of sealing rings

etc. Ensure that any seals are

correctly in place

Any cable gland, stopping gland or

plug, reducer or adapter must be

BASEEFA

(www.hse.gov.uk/eecs/eecshome.ht

m) approved for use with the

apparatus.

6MTechnical

5. Return to

service.

Ensure that any seals are correctly

in place and the correct number

and type of cover bolts are used.

6M 5. Return to

service.

Ensure that any seals are correctly

in place and the correct number

and type of cover bolts are used.

Labels shall be inspected to ensure

that they are legible and to ensure

that the equipment actually fitted is

that

Specified and the source of supply

6MTechnical

Page 240 of 614

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Reason For

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Hazardous areas - EARTHING27-04 27-04 Hazardous areas - EARTHING






carried out in accordance with IEC 60079-19

Added


1. Terminations. Check for continuity and bonding.

See also POWER SUPPLIES -

Earthing.

Earthing of power systems should

be in accordance with BSEN 60079

.

6M 1) Fault loop

impedance or

earthing

resistance

The integrity of the earthing shall be

checked at the initial inspection by

measurement of resistance. The

measurement may be made using

an intrinsically safe resistance

measuring instrument (within the

procedure specified by the

manufacturer). Subsequent sample

inspections may also be carried out

using an intrinsically safe resistance

measuring instrument

Non-intrinsically safe measuring

equipment may be used if a safe

work procedure (see IEC 60079-14)

has been conducted and if the

locations where potentially

incendive sparking could occur, in

case of dust hazards, can be

guaranteed to be free from an

explosive dust atmosphere and

dangerous dust layers by those

responsible for the area.

6MTechnical

a) Earth connections to maintain the

integrity of the intrinsic safety safe

system (such as transformer screen

earth, barrier relay frame earth)

shall be measured. There is no

requirement to measure the earth

loop impedance of mains powered

equipment associated with

intrinsically safe circuits other than

that required for normal control

room instrumentation to protect

against electric shock. Since, in

some equipment, the intrinsic

safety earthing is internally

connected to the equipment frame,

any impedance measurements

(such as between the earth pin of

the plug and the equipment frame,

or the equipment frame and the

control panel) shall be made using

a tester specifically designed for

use on intrinsically safe circuits

6MAdded

Page 241 of 614

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b) Intrinsically safe circuit earthing

and/or insulation

The insulation testing of intrinsically

safe circuits is necessary to confirm

that they are earthed or insulated

from earth throughout, whichever of

these conditions is required by the

original design. This requirement

may be unnecessary if an earth

fault is self revealing, for example, if

a circuit "fails safe" as result of an

earth fault or the circuit uses an

earth leakage monitoring device.

Insulation testing of intrinsically

safe systems or circuits shall only

be carried out using a test device

specifically approved for connection

to such circuits.

Where, in order to carry out these

tests, the common earth connection

to a group of barriers is

disconnected, the tests can only be

made if either the plant is free from

hazard, or if power is removed

completely from all the circuits

which depend upon that common

earth connection. This test is only

required on a sample basis.

6MAdded

Page 242 of 614

HEAT EMITTERS

Page 243 of 614

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HEAT EMITTERS28-01 28-01 HEAT EMITTERS

Fan Convectors, Unit Heaters and Perimeter (skirting) Heating.

Maintenance of heat emitters can be divided into two main areas, namely the fixtures and fittings

directly associated with the supply of heat and the grilles, the heat exchange surfaces through and

over which the air passes. The efficiency of the grilles and heat exchange surfaces can be affected by

fluff and fibres, the severity of which depends upon the location and the environment. Thus a dusty

carpeted room with perimeter skirt heating will require much more frequent cleaning of grilles and

heating surfaces than a lino covered floor in a clean environment. The frequencies shown in the table

below refer to a clean environment but in extreme cases it may be necessary to clean grilles and heat

exchangers as often as once a fortnight.

Fan Convectors, Unit Heaters and Perimeter (skirting) Heating.

Maintenance of heat emitters can be divided into two main areas, namely the fixtures and fittings

directly associated with the supply of heat and the grilles, the heat exchange surfaces through and

over which the air passes. The efficiency of the grilles and heat exchange surfaces can be affected by

fluff and fibres, the severity of which depends upon the location and the environment. Thus a dusty

carpeted room with perimeter skirt heating will require much more frequent cleaning of grilles and

heating surfaces than a lino covered floor in a clean environment. The frequencies shown in the table

below refer to a clean environment but in extreme cases it may be necessary to clean grilles and heat

exchangers as often as once a fortnight.




safety and health hazard, as undetected CO is poisonous.

Technical


7. TRV`s Check air temperature calibration

against surface temperature of heat

emitter. Advise client if air flow

around sensor is restricted or

affected by any reflected or other

thermal gains. Check operation of

thermostatic radiator valves.

Low temperature surfaces for heat

emitters are desirable in homes for

senior citizens/disabled.

12MAdded

8. General. Leave unit in good working order. Report on any further work

considered necessary.

12MAdded

Fan convectors

[electric]

12MAdded

1. Casing Examine condition of casing,

access panels and grilles. Check

unit is secure, free from dust and

dirt especially at air inlet and

discharge grilles.

12MAdded

2.Controls Check all thermostats and other

controls operate satisfactorily and

are set in accordance with

specification.

12MAdded

3.Fan Inspect air circulation fan set(s),

check fan/motor assembly for

damage and for correct alignment.

Check for wear at any resilient

mounts.

12MAdded

4. Heat exchanger Examine heater battery/element,

clean and comb as required.

12MAdded

Page 244 of 614

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7. Electrical Heater Unit Check function &

operation of local isolation device

(stoplock/isolator). Examine and

report condition of all associated

wiring, ensure security of all

terminal connections and check for

satisfactory condition of any flexible

cables/conduits. Ensure plant has

adequate earth conductor and

bonding is secure. Take and log

motor current and compare with

nameplate details. Check all

temperature control devices for

correct operation and function.

12MAdded

5. TRV’s Check air temperature calibration




effected by any reflected or other

thermal gains. Check operation of

thermostatic radiator valves.




12MAdded

Fan Convectors Fan Convectors

(LTHW or Steam)

Other

1. Casing. Examine condition of casing,

access panels and grilles.

Check parts are securely fastened

and free from `rattles'. Check

condition of access panels. Clean

inside of casing. If unit has loose

grilles, check seal between unit and

grilles to ensure no air leakage or

short circuiting occurs.

12M 1. Casing. Examine condition of casing,

access panels and grilles. Check

unit is secure.


and free from `rattles`. Check






12MOther

3. Filters. When fitted remove, examine and

check for damage. Clean or

replace.

Check if filter is cleanable or

throwaway type. The frequency of

cleaning depends upon the dirtiness

of the air. Normally cleaning should

be every two months but more


necessary.

3M 3. Filters. When fitted remove, examine and


replace.


disposable type. The frequency of



be every three months but more


necessary.

3MOther

4. Heat

exchanger.

Inspect and clean. Purge air from

hot water units.

Clean using an industrial vacuum

cleaner. Draw air through the heat

exchanger in the opposite direction

to the normal air flow. In exceptional

cases a high pressure air hose may

be required. In a dirty environment

more frequent cleaning will be

needed, e.g. quarterly, six weekly or

even monthly. advance \U 0.0 -

WHAT DOES THIS MEAN?

3M 4. Heat

exchanger.


hot water units.





cases a high pressure air hose may

be required. In a dirty environment



even monthly.

3MTechnical

6.Pipework,

valves, steam

traps and

associated

equipment.

Examine for corrosion or leaks.

Where applicable clean steam

traps, strainers, non return valves

and scale pockets.

Check operation of steam traps.

Check operation of thermostatic

radiator valves (TRVs)

12M 6.Pipework,

valves, steam

traps and

associated

equipment.




and scale pockets.

Check operation of steam traps.12MTechnical

Page 245 of 614

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12M Deleted


discharge louvres and inlet guards.

Where applicable, check condition

of any flexible ducting connections.

Check security of mounting brackets

or drop rods. Check that any

discharge louvres are correctly set

to give the desired air spread

pattern.


discharge louvers and inlet guards.

check unit is secure and that all

bolts, nuts, setscrews etc. for

security. Check and clean surfaces

of unit casing, check for corrosion,

repair and treat as found

necessary. Ensure all access doors

for fit and can be made secure.

When shut, ensure for air tight seal.

Where applicable, check condition

of any flexible ducting connections.

Check security of mounting brackets

or drop rods. Check that any

discharge louvers are correctly set

to give the desired air spread

pattern.

12MTechnical

3. Heat

exchanger.


hot water units.





cases a high pressure hose may be

required. In a dirty environment



even monthly.

3M 3. Heat

exchanger.


hot water units.




to the normal air flow. In

exceptional cases a high pressure

hose may be required. In a dirty

environment more frequent cleaning

will be needed, e.g. quarterly, six

weekly or even monthly. Vent coil at

local air vent. If automatic air vent

provided, check for correct

operation.

3MTechnical

4. Filters. When fitted remove, examine and


replace.


throwaway type. The frequency of



be every two months but more


necessary.

3M 4. Filters. When fitted remove, examine and


replace.


disposable type. The frequency of



be every three months but more


necessary.

3MTechnical

5. Motor/fan

assembly.

Lubricate bearings where

applicable.

Check security of fans and condition

of resilient mounts.

6M 5. Motor/fan

assembly.

Checking fan/motor bearings for

abnormal wear. Cleaning all

surfaces, particularly fan impeller

and motor casing vents. Lubricate

fan/motor bearings where grease

nipples/lubricators are fitted, taking

care not to over-grease. Lightly

grease fan motor slide rails.

Check security of fans and condition

of resilient mounts.

If applicable:

Check condition, tension and

alignment of drive belts and pulleys.

Renew drive belts as necessary.

Check drive guard is in good repair

and securely fixed, providing correct

cover of all moving parts

6MTechnical



12M 8. General. Leave unit in good working order.

After maintenance, carry out a

general operational check, and

check for excessive noise, vibration

and temperature.

Report on any further work


12MTechnical


access panels and grilles. Where

applicable, check condition of

damper seal.


and free from `rattles'. Check







access panels and grilles. Where

applicable, check condition of

damper seal. Check unit is secure.


and free from `rattles`. Check






12MOther

Page 246 of 614

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3. Pipework,

valves, steam

traps and

associated

equipment.




and scale pockets.

Check operation of steam traps.

Check operation of thermostatic

radiator valves (TRV s).

12M 3. Pipework,

valves, steam

traps and

associated

equipment.




and scale pockets.

Check operation of steam traps.12MOther



12M 6. General. Leave unit in good working order. Report on any further work


12MOther

ALL ITEMS Cleaning and maintenance. Due to possible difficulties of access

cleaning and maintenance should

only be undertaken by competent

person. advance \U 0.0 - WHAT

DOES THIS MEAN? When

applicable, isolate units(s) from

electrical supply by removing fuses

or locking main switch in OFF

position. Always refer to the

manufacturer's

instructions/recommendations

before undertaking any cleaning or

maintenance.

12M All items Cleaning and maintenance. Due to possible difficulties of access

cleaning and maintenance should

only be undertaken by competent

person. When applicable, isolate

units(s) from electrical supply by

removing fuses or locking main

switch in OFF position. Always refer

to the manufacturer`s

instructions/recommendations

before undertaking any cleaning or

maintenance.

12MOther

Page 247 of 614

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GAS FIRED CERAMIC PLAQUE INFRA RED HEATERS28-02 28-02 GAS FIRED CERAMIC PLAQUE INFRA RED HEATERS

These heaters are usually placed high up in a building and consequently are not easily accessible. A

risk assessment and method statement should be carried out. Access by stepladders is not

recommended. Regular maintenance is essential and whilst annual maintenance may be adequate in

a clean environment, dusty conditions will require more frequent maintenance. In very dusty

environments, e.g. textile factories, it may be more desirable to duct a direct combustion air line to the

heater






heater.





Other


1. Ceramic

plaques.

Clean using an 80 p.s.i. air supply. The direction of air flow should be

opposite to that of the gas flow.

12M 2. Ceramic

plaques.

Clean using an air supply. The direction of air flow should be

opposite to that of the gas flow.

12MOther

2. Electrical spark

plug.

Clean with wire brush, replace if

there are any signs of corrosion.

12M 3. Electrical

spark plug.

Clean with wire brush, replace if

there are any signs of corrosion.

Check spark electrode gap for

satisfactory setting, refer to

manufacturer`s manual.

12MOther

3. Connecting

wires.

Check for damage. If there are any signs of

deterioration, replace.

12M 4. Wiring and

controls.

Check for satisfactory operation of

local electrical isolation switch.

Check function and operation of all

control switches and temperature

controls. Examine and report

condition of all associated wiring,

ensure security of all terminations

and check for satisfactory condition

of any flexible cables/conduits.

Ensure plant has adequate earth

conductor and bonding is secure.

12MOther

4. Gas pressure. Check with rated value and adjust if

necessary.

The rated value will be found on the

identification plate or in the

operating instructions.

12M 5. Gas pressure,

gas pipework and

cocks

Check with rated value and adjust if

necessary. Check gas cocks are

free to turn, lubricate as necessary.

Inspect gas pipework system,

check for leaks, loose brackets and

supports, repair as necessary,

report all findings.




12MOther

5. Performance

check.

Switch on and when stable plaque

should present a uniform cherry red

appearance.

If the unit does not perform correctly

the plaques should be cleaned. If

the specified output is not obtained

the unit should be replaced and

returned to the manufacturer. Under

certain conditions, e.g. broken

plaque, the heater may light back,

i.e. gas may ignite at the injector

resulting in flames being vented

from the exhaust of the heater.

Apart from the lack of radiant effect

light back will cause blockage of the

plaque with carbon.

12M 6. Performance

check.

Switch on and when stable plaque

should present a uniform cherry red

appearance.

If the unit does not perform correctly

the plaques should be cleaned. If

the specified output is not obtained

the unit should be replaced and

returned to the manufacturer. Under

certain conditions, e.g. broken

plaque, the heater may light back,

i.e. gas may ignite at the injector

resulting in flames being vented

from the exhaust of the heater.

Apart from the lack of radiant effect

light back will cause blockage of the

plaque with carbon.

12MOther

Page 248 of 614

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1. General check unit is secure and that all

bolts, nuts, setscrews etc. for

security. Check and clean surfaces

of unit, check for corrosion, repair

and treat as found necessary.

12MAdded

Page 249 of 614

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GAS RADIANT TUBE HEATERS28-03 28-03 GAS RADIANT TUBE HEATERS






heater.





Added


17. Wiring and

Controls











conductor and bonding is secure

12MAdded

1. Isolation of

heater from

electrical and gas

supply.


off gas supply.

For safety reasons it is essential

that the equipment is isolated from

electricity and gas before servicing.

12M 1. General and

Isolation of heater

from electrical and

gas supply


off gas supply.

Inspect emitter tube and brush any

dust from the exterior of the emitter

tube. Inspect the emitter tube

internally, clean with a vacuum

cleaner as found necessary.

Inspect and clean injector using a

soft brush. Inspect and clean as

necessary the burner fresh air duct

(where fitted) and air inlet terminal.

Inspect radiant tubes and fittings

internally. If there is any

appreciable build up of dust or

deposits the tubes should be

cleaned internally. If corrosion is

present replace as necessary.

Inspect for evidence of holes and

cracks to tube couplers and replace

if necessary.

For safety reasons it is essential

that the equipment is isolated from

electricity and gas before servicing.

12MTechnical

Page 250 of 614

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6. Spark plug. Remove, clean and refit. Check ceramic for cracks or

breakage. Renew if necessary.

12M 6. Spark plug

spark plug and

burner electrode

assembly

Remove, clean and refit.

Check spark electrode gap for

satisfactory setting, refer to

manufacturer`s manual. Inspect

burner electrode assembly, check

electrodes for build up of carbon or

cracks. Check the spark distance

and position of electrodes relative

to the burner head. Renew

electrode assembly if not in good

condition.

Check ceramic for cracks or

breakage. Renew if necessary.

12MTechnical

9. Observation

windows.

Check and clean12M 9. Observation

windows.

Clean combustion chamber viewing

window.

12MTechnical

11. Acoustic

joints.

Check for wear. Renew if necessary.12M 11. Acoustic

joints.

Inspect acoustic joints for damage


Renew if necessary.12MTechnical

12. Condensate

traps.

Check for blockages.12M 12. Condensate

traps.

Inspect condensate trap for

blockages, dirt and scale, clean if

necessary.

12MTechnical

13. Vacuum

motor pump.

If fitted, examine mountings Lubricate pump motor if applicable.12M 13. Vacuum

motor pump.

If fitted, examine mountings.

Inspect vacuum fan and flue

ductwork for any contamination.

Lubricate pump motor if applicable.12MTechnical

14. Reflectors. Inspect to ensure correct fitting.12M 14. Reflectors. Inspect to ensure correct fitting and

Clean with soft cloth and detergent

in water.

12MTechnical

15. Gas test. Pressure drop test back to nearest

gas cock to ensure soundness.

12M 15. Gas

pressure, gas

pipework and

cocks

Pressure drop test back to nearest

gas cock to ensure soundness.

Check gas cocks are free to turn,

lubricate as necessary.




report all findings

12MTechnical

16. General. Undertake heat test. With heater(s) switched on and

system stabilised carry out a heat

test in accordance with the

manufacturer s recommendations.

Check all burner units for correct

ignition sequence pilot and main

burner flames for stability and

correct aeration, adjust if necessary.

The following readings are to be

taken and the system adjusted to

meet the manufacturer s

recommendations: - -vacuum at

each end vent - -maximum and

minimum pressure - -gas

consumption

12M 16. General. After cleaning and adjustment,

re-assemble, cleaning the reflector

plate. Check all auxiliary controls/

gas shut-off devices. Undertake

heat test.

With heater(s) switched on and

system stabilised carry out a heat

test in accordance with the

manufacturer s recommendations.

Check all burner units for correct

ignition sequence pilot and main

burner flames for stability and

correct aeration, adjust if necessary.

The following readings are to be

taken and the system adjusted to

meet the manufacturer s

recommendations: - -vacuum at

each end vent - -maximum and

minimum pressure - -gas

consumption

12MTechnical

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GAS FIRED NATURAL AND FAN ASSISTED HEATERS - Conventional and

Balanced Flue.

28-04 28-04 GAS FIRED NATURAL AND FAN ASSISTED HEATERS - Conventional and

Balanced Flue.






heater.





Added


5. Thermocouple. Clean with fine wire brush

reassemble pilot and test.

Renew with manufacturer s

approved thermocouple if

necessary.

12M 5. Thermocouple. Clean with fine wire brush

reassemble pilot and test.

Renew with manufacturer’s

approved thermocouple if necessary

12MTechnical

11. General. Check settings and correct

operation of thermostats and time

clocks.

Make necessary corrections if

required.

12M 13. General. Check settings and correct

operation of thermostats and time

clocks.

Make necessary corrections if

required.

12MOther

11 Gas pressure,

gas pipework and

cocks

Check with rated value and adjust if

necessary. Check gas cocks are

free to turn, lubricate as necessary.




report all findings.




12MAdded

12. Wiring and

Controls












12MAdded

Page 252 of 614

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28-05 GAS FIRE

Carbon Monoxide (CO) is poisonous, life threatening and also causes energy waste. Flames should

be bluish and burning in a stable manner. The fire should be quiet in operation, no excessive noise

should occur when the fire ignites or shuts down.


50292:2002.

Added


1. Vent and Flu. Check ventilation arrangements are

adequate and not blocked. Check

flue termination and that it is

compliant.

12MAdded

2. General Remove the outer case and the

radiant`s or fuel. Check for soot and

rubble behind the closure plate and

clean out if necessary (excessively

large quantities can block the fuel

spigot and cause spillage). Reseal

the closure plate if required,

ensuring that the relief opening is

clear. Clear dirt and lint from the

base of the fire where the cool air

enters from the room.

12MAdded

3. Burner and

injectors

Clean dust and lint from the burner

and the injectors

12MAdded

4. Heat Exchanger Check the heat exchanger for

corrosion damage and clean the

visible flueway.

12MAdded

5. Gas tap Check shut off. Grease gas tap if it

is stiff to turn.

12MAdded

6. Refit fire Reconnect the fire and check for

gas soundness.

Ensure fire is level and secure.

12MAdded

7. Ignition Test the ignition, clean or renew any

batteries or parts as necessary.

Check any electrical components;

wires should be properly insulated,

connections clean and sound. Test

any spark gap and reset if

necessary.

12MAdded

8. Burner pressure Check gas rate by burner pressure

and adjust governor if required

12MAdded

9. Controls Check the operation of any flame

supervision device, if fitted. Check

that thermostat phial is correctly

located and that thermostat

operates satisfactorily.

12MAdded

10. Radiant`s and

case

Replace radiant`s and case.12MAdded

Page 253 of 614

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Reason For

Change

11. Flue Check flue pull.12MAdded

Page 254 of 614

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28-06 GAS FIRED UNIT HEATERS

The frequency will change depending on the amount of dust in the atmosphere.





50292:2002.

Added


1. Burner

assembly

Remove the burner assembly and

clean thoroughly. Check the

condition of the ignitor and clean to

remove all deposits. Check spark

gap and adjust as required to the

manufacturers guide. Check the

sensor and clean as necessary.

Remove any soot deposits from the

burner with a wire brush. Clean the

ports with a degreaser or acetone.

Wipe the inside of the burner tube

clean (cleaning thoroughly with a

degreaser as recommended will

retard future buildup of dirt). Inspect

burner for any damage or

deterioration. If the burner is

damaged or corroded it will need to

be replaced.

Stubborn deposits on the burners

are often best cleaned using

"acetone" as a solvent.

A vacuum cleaner or compressed

air may assist in this cleaning

operation.

12MAdded

2. Heat Exchanger Examine the heat exchanger tubes

internally and externally for any sign

of deterioration. Remove any dust

and grease deposits. Clean the

inner surfaces of the heat

exchanger with a flue brush and

remove all deposits.

The heat exchanger should remain

clean unless a problem has

developed due to poor combustion.

12MAdded

3. Fan Clean the axial fan blades, fan

guard and fan motor to remove all

external dirt. Check the security of

the fan on the motor. Most fan

motors are lubricated for life and do

not require lubricating but check

manufacturers guidelines.

12MAdded

4. Venter Fan Remove any dirt and/or grease that

may have accumulated on the

venter fan motor and its housing.

Most venter fan motors are

lubricated for life and do not require

lubricating but check manufacturers

guidelines.

12MAdded

5. Control valve Clean the exterior of the gas control

valve and check the condition of the

wire connections. Test pressure as

manufacturers instructions.

12MAdded

Page 255 of 614

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6.

Flue/combustion

air

Check the flue/combustion air

system for soundness.

Reseal/replace any parts that are

not sound.

12MAdded

7. Wiring Check all wiring connections.

Check wiring for any signs of

damage. Replace any suspect

wiring with equivalent specification.

12MAdded

8. Controls Check operation of the thermal fan

control and control relay.

12MAdded

9. recommission

unit

When the service is complete carry

out full commissioning as per

manufacturers commissioning

procedure.

12MAdded

Page 256 of 614

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Reason For

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28-07 GAS FIRED RADIANT HEATERS

The frequency will change depending on the amount of dust in the atmosphere.





50292:2002.

Added


1. Vent and Flue. Check ventilation arrangements are

adequate and not blocked. Check

flue termination and that it is

compliant. Inspect and clean as

necessary the burner fresh air duct

(where fitted) and air inlet terminal.

12MAdded

2. Burner, injectors

and pilots

Clean the burner, injectors and the

pilots. Check burner electrodes for

build up of carbon or cracks.

Check the spark distance and

position of electrodes relative to the

burner head. Check condition of

burner head insert and flame

retention grid and replace if

necessary.

Replace filter unit if contaminated

with dirt. Clean combustion

chamber viewing window.

12MAdded

3. Gas tap and

pipework

Check shut off. Grease gas tap if it

is stiff to turn. Inspect gas pipework

system, check for leaks, loose

brackets and supports, repair as

necessary, report all findings.

12MAdded

4. Ignition Test the ignition, clean or renew any

parts as necessary. Check any

electrical components; wires should

be properly insulated, connections

clean and sound. Test any spark

gap and reset if necessary.

12MAdded

5. Burner pressure Check gas rate by burner pressure

and adjust governor if required

12MAdded

Page 257 of 614

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6. Controls and

wiring





controls. Check the operation of

any flame supervision device, if

fitted. Check that thermostat phial is

correctly located and that

thermostat operates satisfactorily.

Examine and report condition of all

associated wiring, ensure security

of all terminations and check for




bonding is secure.

12MAdded

7. Reflectors Clean and polish reflectors.12MAdded

8. Ceramic

plaques

Clean ceramic plaques. Dust from the atmosphere builds up

on the rear face of the ceramic

plaques and can cause local

overheating and light-back. It may

be removed by a fine jet of

compressed air at a pressure of

about 5.5 bar. This should be

directed first into the holes in the

plaque and then into the venturi and

finally into the holes again.

Care must be taken not to damage

the plaque or dislodge the sealing

material holding it to the burner

body. Some manufacturers

recommend washing the plaques

using a detergent. It may be

necessary to replace damaged or

badly linted plaques. This is best

done on a bench. The new plaque

must be sealed by the material

appropriate to the particular model

which may be metal strips,

fireproof cement or insulating

material.

12MAdded

9. Combustion air

fan

Inspect heater`s fan assembly, strip

and clean as found necessary.

Check operation, check wiring and

clean casing and blades if possible.

Lubricate bearings in accordance

with manufacturer`s

recommendations using the correct

type of oil they specify.

12MAdded

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10. Suspension

chains, brackets

etc.

Check they are secure.12MAdded

11. Emitter tube Inspect emitter tube and brush any

dust from the exterior of the emitter

tube. Inspect the emitter tube

internally, clean with a vacuum

cleaner as found necessary.

12MAdded

Page 259 of 614

HEAT EXCHANGERS

Page 260 of 614

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HEAT EXCHANGERS - COILS29-01 29-01 HEAT EXCHANGERS - COILS

Note:- When cleaning ensure that system fans are off to avoid dirt disturbed during cleaning

entering into the system

When cleaning ensure that system fans are off to avoid dirt disturbed during cleaning entering into the

system

Technical


5. Coil vent. Check operation, condition of filters

and sight glasses.

6MAdded

6. Pipework Inspect connections, pipes and



necessary.

12MAdded

5. Pipework Inspect connections, pipes and



necessary

12MAdded

5. Flues Service. For detailed information on

maintenance of Flues see Flues

SFG 24-01.

12MAdded

a) external surface

air side,

Clean coils and comb out fins. Where necessary clean with

appropriate sterilising solution,

especially when coils operated

under moist air conditions or act as

a dehumidifier.

12M a) external surface

air side,

Clean coils by blowing through with

dry, oxygen free, nitrogen from the

opposite side to the air flow. Comb

out fins. Where Nitrogen is used, a

Risk Assessment must be done

prior and suitable training given.

Where necessary clean with

appropriate sterilising solution,

especially when coils operated

under moist air conditions or act as

a dehumidifier. Particularly dirty

coils should be reported to the client

as the filter changing regime may

need to be amended.

12MTechnical

a) external surface

air side,

Clean coils and comb out fins. Where necessary clean with

appropriate sterilising solution.

12M a) external surface

air side,

Clean coils by blowing through with

dry, oxygen free, nitrogen from the

opposite side to the air flow. Comb

out fins. Where Nitrogen is used, a

Risk Assessment must be done

prior and suitable training given.

Where necessary clean with

appropriate sterilising solution.

Particularly dirty coils should be

reported to the client as the filter

changing regime may need to be

amended.

12MTechnical

b) water side. Flush out coils to remove sediment. Report to client on any further action

necessary due to scale or erosion.

12M Deleted

3. Coil casing. Inspect for rust and clean and

repaint as required.

12M 2. Coil casing. Inspect for rust and clean and


12MOther

4. Coil mounting

bolts.

Check for tightness and secure if

necessary.

Corroded bolts should be replaced.12M 3. Coil mounting

bolts.

Check for tightness and secure if

necessary.

Corroded bolts should be replaced.12MOther

5. Operation of

steam traps.

Check operation, condition of filters

and sight glasses.

Full details of maintenance

requirements steam services, see

PIPEWORK SYSTEMS.

1M 4. Operation of

steam traps.


and sight glasses.

Full details of maintenance

requirements steam services, see

Pipework systems SFG 40-11.

1MOther

5. Operation of

steam traps.


and sight glasses.

1M Deleted

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a) air side, Clean fins and air-side surfaces. Comb fins if appropriate. Where

necessary clean with appropriate

sterilising solution.

12M a) air side, Clean coils air-side surfaces by

blowing through with dry, oxygen

free, nitrogen from the opposite

side to the air flow. Where Nitrogen

is used, a Risk Assessment must

be done prior and suitable training

given.

Comb fins if appropriate. Where


sterilising solution. Particularly dirty



need to be amended.

12MOther

4. Gas burners

and associated

equipment.

Service. For detailed information on

maintenance of gas fired heater see

relevant gas burner.

12M 4. Gas burners

and associated

equipment.

Service. For detailed information on

maintenance of gas fired heater see

relevant gas burner see Burners

SFG 07.

12MOther

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ELECTRIC/AIR HEATER29-02 29-02 ELECTRIC/AIR HEATER

Note: When cleaning, ensure that system fans are off to avoid dirt disturbed during cleaning

entering the system.

When cleaning ensure that system fans are off to avoid dirt disturbed during cleaning entering into the

system

Technical


1. Terminal box: 2. Terminal box:Technical

2. Elements: 3. Elements:Technical

a) within terminal

box,

Check insulation resistance of each

element. Check continuity.

Replace if below 1 megohm

resistance. Replace if open circuit.

12M a) within terminal

box,

Check insulation resistance of each

element. Check continuity.

Replace if below 1 meg ohm

resistance. Replace if open circuit.

12MTechnical

3. Casing. Inspect for rust and clean and


12M 4. Casing. Inspect for rust and clean and


12MTechnical

4. Mounting bolts. Check for tightness and secure as

necessary.

Examine casing mounting flanges

for air tightness where appropriate.

12M 5. Mounting

bolts.

Check for tightness and secure as

necessary.

Examine casing mounting flanges

for air tightness where appropriate.

12MTechnical

5. Thermostats/

controls.

Check operation. For detailed maintenance see

relevant section.

12M 6. Thermostats/

controls.

Check operation. For detailed maintenance see

relevant section Sensors and

switching devices SFG 50

12MTechnical

1. air side, Clean coils air-side surfaces by

blowing through with dry, oxygen

free, nitrogen from the opposite

side to the air flow. Where Nitrogen

is used, a Risk Assessment must

be done prior and suitable training

given.

Comb fins if appropriate. Where


sterilising solution. Particularly dirty



need to be amended.

12MAdded

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PLATE RECUPERATOR29-03 29-03 PLATE RECUPERATOR


2. Internal

surfaces.

Check and remove any dirt, inspect

for rust and repaint as necessary.

Do not use wire brush for dirt

removal, blow off with dry nitrogen

or compressed air.

6M 2. Internal

surfaces.

Check and remove any dirt, inspect

for rust and repaint as necessary.

Do not use wire brush for dirt

removal, blow off with dry nitrogen

or compressed air. Where Nitrogen

is used, a Risk Assessment must be

done prior and suitable training

given.

6MTechnical

5. Fans. Service and lubricate.6M 5. Fans. Service and lubricate. For further guidance see Fans SFG

20

6MTechnical

9. Filters. Clean or replace as necessary. Filters are fitted on both inlet and

extract to keep the heat exchangers

clean.

3M 9. Filters. Clean or replace as necessary. Filters are fitted on both inlet and

extract to keep the heat exchangers

clean.

In normal use, air filters do not

present a health and safety hazard.

However used air filters do contain

quantities of dust which, unless

precautions are taken, may expose

maintenance personnel to a

`nuisance dust hazard`, as defined

by the Control of Substances

Hazardous to Health (COSHH )

Regulations. A risk assessment

must be carried out before the work

starts and a method statement

produced. Used filters must be

regarded as Controlled Waste and

appropriate safeguards taken for

their disposal.

3Mlegislative

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THERMAL WHEELS - ROTARY HEAT REGENERATORS29-04 29-04 THERMAL WHEELS - ROTARY HEAT REGENERATORS


1. Bearings. Lubricate according to the


'Sealed for life' bearing should not

need any maintenance.

6M 1. Bearings. Lubricate according to the


Sealed for life` bearings should not

need any maintenance.

6MOther

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RUN AROUND HEAT RECOVERY COILS29-05 29-05 RUN AROUND HEAT RECOVERY COILS


1. Pump. Inspect bearings for wear. Check

flow rates/speed and leak

tightness. Check electrical

connections.

Frequency should be in accordance

with the manufacturer's instructions.

Observe correct safety procedures

as required under the Electricity at

Work Regulations.

12M 1. Pump. Inspect bearings for wear. Check

flow rates/speed and leak tightness.

Check electrical connections.

Frequency should be in accordance

with the manufacturer`s instructions.

Observe correct safety procedures

as required under the Electricity at

Work Regulations. For further

guidance see Pumps SFG 45.

12MOther

3. Water. Check for leaks. Remedy if possible, if major

problem, refer to client.

12M 3. Water. Check for leaks. Remedy if possible, if major

problem, refer to client .

12MOther

4. Operating

pressure.

Check. Confirm pressure vessel operating

conditions.

12M 4. Operating

Pressure

Check and record. Confirm pressure vessel operating

conditions. A written scheme of

examination may be required for the

system.

12MTechnical

5. Coils. Clean with recommended cleaning

compound and flush with water.

12M 5. Coils Clean with recommended cleaning

compound and flush with water.

12MOther

6. Air. Check for leaks. Rectify as required providing new

seals etc.

12M 6. Air Check for leaks. Rectify as required providing new

seals etc.

12MOther

7. Condensate

traps.

Inspect for rust, clean and clear any

debris. Recoat. Check traps are

filled with water on return to

service.

12M 7. Condensate

traps

Inspect for rust, clean and clear any

debris. Recoat. Check traps are

filled with water on return to service.

12MOther

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PLATE HEAT EXCHANGERS29-06 29-06 PLATE HEAT EXCHANGERS


14. Check safety

controls.

Safety valve operation.12M 14. Check safety

controls.

Check Safety valve operation.12MTechnical

Page 267 of 614

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WATER TO WATER PLATE HEAT EXCHANGERS29-07 29-07 WATER TO WATER PLATE HEAT EXCHANGERS

Page 268 of 614

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29-08 HEATING CALORIFIERS - MTHW, HTHW or STEAM

Most MTHW, HTHW and Steam Calorifiers will be under the control of an Authorised Person. A permit

to Work must be issued by the Authorised Person before any work can commence on a Calorifier

If insulation looks damaged - STOP WORK- this may be Asbestos - Appropriate action must be taken

prior to further works. If the insulation is known or CERTIFIED not to be Asbestos, continue as follows:

-

See SFG 32-01 for further information on temperatures etc.

Prior to carrying out the planned maintenance of the calorifier, the pre-maintenance procedure

detailed below should be followed:

(a) At the entrance to the Plant room, Stop and Listen for a steam leak (High Pressure steam will be

invisible and only the sound of a leak may be present)

(b) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from

system) including safety.

(c)Inspect calorifier insulation and/or shell for signs of damage.

(d)Inspect all manholes, mounting and joints for signs of leaks.

(e) Report any necessary remedial work where repairs, adjustment or replacement will be required

during routine maintenance.

Added


1. Check

operation, in

particular safety

controls.

Check, note and report any visible

defects.

Ensure secondary is full of water

and circuits are open. If safety

controls are defective take

equipment out of service.

12MAdded

2. Safety valves. Check for corrosion and manually

operate.

If calorifier was in use, the

secondary water will be hot and can

be under pressure, so care must be

taken in carrying out this item of the

schedule.

12MAdded

3. Thermostats,

pressure sensors,

altitude gauges

and thermometers.


settings, set against Certified

masters.

12MAdded

4. Auto controls

and primary side.

Shut down primary heat source

taking all necessary precautions to

prevent unauthorised use.

Check safe operation of

temperature controls and high limit

cut-outs. This may include obtaining

a Permit to Work from an Authorised

Person.

12MAdded

5. Drain

valve/drain cock

on secondary side.

Draw off a small quantity of water to

remove any sediment.





schedule.

12MAdded

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6. Heating

surface and

internal surfaces

of shell.

Drain down secondary side, remove

manhole covers and inspect for

scale formation and corrosion.

The formation of scale reduces heat

transfer and causes energy

wastage. Client`s attention should

be drawn to the presence of

excessive scale which indicates the

need for water treatment. Corrosion

will cause metal failure and leakage.

Remember Waste Disposal

Legislation. If scale is extensive,

refer to client for further instructions.

12MAdded

7. Gaskets. Check gaskets on steam chest for

leakage, replace as necessary.

Steam leaks are dangerous to

personnel and cause wastage of

energy.

12MAdded

8. Sacrificial

anode.

Check status. Replace as necessary.12MAdded

9. Steam

trap/sight glass

(on primary

connections).

Clean and overhaul steam trap. Faults can lead to steam and energy

wastage.

12MAdded

10. Strainer on

primary pipework.

Remove strainer, clean and refit. Blocked strainers reduce

performance.

12MAdded

11. Internal

Inspection

Arrange for an internal inspection to

be carried out by a Competent

Person as required by the Written

Scheme of Examination.

Pressure Systems Safety

Regulations 2000 will apply.

12MAdded

12. Primary

heating coil

Test primary heating coil.12MAdded

13. Return to

operation.

After completion of maintenance,

refit all manhole covers and put

back into operation.

Check that all controls are working

correctly.

12MAdded

14. Check

insulation for

damage.

Repair or renew as necessary. Damaged lagging reduces

efficiency, wastes heat, and if the

calorifier is in the open air, can

become waterlogged and lead to

hidden corrosion. Asbestos


12MAdded

15. Hydraulic

pressure test.

If a pressurised system test to

110% of working pressure.



12MAdded

Page 270 of 614

HEAT REJECTION SYSTEMS

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This section covers those items of plant associated with the removal of heat from the equipment

producing the cooling. It covers evaporative/wet cooling towers, dry coolers and condensers. Where

cooling towers have been, or appear to have been poorly maintained in the past, there is a danger

that Legionella bacteria may be present, it is therefore essential that appropriate safety procedures as

listed in ACOP L8,2001 must be followed.

Waterside fouling will vary with the hardness of the water, amount of bleed off and the quantity of

make up. In hard water areas or where heavy air pollution occurs it may be necessary to increase the

maintenance frequency.

This section covers those items of plant associated with the removal of heat from the equipment

producing the cooling. It covers evaporative/wet cooling towers, dry coolers and condensers. Where

cooling towers have been, or appear to have been poorly maintained in the past, there is a danger

that Legionella bacteria may be present, it is therefore essential that appropriate safety procedures as

listed inACOP L8,2000 (www.hse.gov.uk) must be followed.

The cooling system may consist of a cooling tower, evaporative condenser or other cooling element,

the recirculating pipework, the heat exchanger, pumps and ancillary items such as supply tanks and

pre-treatment equipment. All of these items should be subject to the management and control system.

Cooling systems and towers should be kept in regular use wherever possible. Where a system is used

intermittently or is required at short notice, it should be run once a week and, at the same time, be

dosed with water treatment chemicals and water quality monitored. The whole system should be run

for long enough to thoroughly distribute treated water. If a system is out of use for a week or longer

(up to a month), in addition to the above, the water should be treated with biocide immediately on

reuse.

If it is out of use for longer than a month and there are continued management/monitoring

arrangements in place, the system should be kept full of treated water which should be checked (for

biocide levels and water quality) and circulated once a week (see also paragraph 135). If it is not

possible to ensure regular monitoring and circulation (for example if a building falls out of use) the

system should be drained and sealed, with a desiccant left in the system to reduce the effects of

corrosion. Full recommissioning will be required before the system can be bought back into reuse.

Cooling systems that do not operate continuously, such as cooling towers that cycle on and off

automatically or those on regular standby duty, require particular attention with regard to the biocide

programme to ensure that effective levels of biocide are maintained at all times .

Waterside fouling will vary with the hardness of the water, amount of bleed off and the quantity of

make up. In hard water areas or where heavy air pollution occurs it may be necessary to increase the

maintenance frequency.

technical

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COOLING TOWERS - Precautions against Legionnaires disease (legionella

pneumophila)

30-02 30-02 COOLING TOWERS - Precautions against Legionnaires disease (legionella

pneumophila)

Action to be taken prior to the visit.

I. Notify appropriate local and/or water authority/company, prior to discharging water drained from the

cooling tower as the contaminated water could enter sewers.

II. Advise client that cooling tower will be out of action during period of visit.

Note:- Towers that have not been regularly maintained must be treated as HAZARDOUS and must

not be maintained by personnel who may be susceptible to LEGIONELLA.


Approved Code of Practice, L8 sets out certain statutory requirements. In particular each water




guidance.

Action to be taken prior to the visit.

I. Notify appropriate local and/or water authority/company, prior to discharging water drained from the

cooling tower as the contaminated water could enter sewers.

II. Advise client that cooling tower will be out of action during period of visit.

Towers that have not been regularly maintained must be treated as HAZARDOUS and must not be

maintained by personnel who may be susceptible to LEGIONELLA.

Technical


Initial Safety

Precautions

Ensure Competent fully trained

maintenance personnel read ACOP

L8, 2001. Select personnel who are

less susceptible to the disease.

Protecting clothing and positive

pressure respirators.

Cooling water Analysis

Before starting work on cleaning

cooling towers it is essential that

certain preliminary safety

precautions are taken. These are

listed under 'Action'.

Personnel must wear positive

pressure respirators when

contamination is suspected or the

condition is not known. Note:-

respirator seal may not work with

beards.

Sample and send to a UKAS

accredited laboratory for total viable

colony count (TVC) Dipslides should

be taken weekly.

Initial Safety

Precautions

Ensure Competent fully trained

maintenance personnel read ACOP

L8, 2000 (www.hse.gov.uk).

Before starting work on cleaning

cooling towers it is essential that

certain preliminary safety

precautions are taken. These are

listed under `Action`.

Personnel must wear positive

pressure respirators when

contamination is suspected or the

condition is not known. Note:-

respirator seal may not work with

beards.

Sample and send to a UKAS

(www.ukas.com) accredited

laboratory for total viable colony

count (TVC) Dipslides should be

taken weekly.

Legislative

Page 273 of 614

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Cleansing and

disinfection

procedures

Where cooling towers are situated in

rural areas and only in use during

the summer months the frequency

of maintenance can be extended to

twelve months.

Cleansing and

disinfection

procedures

Disinfection, cleaning and manual

desludging of cooling towers should

be undertaken at least twice a year,

but more frequent cleaning may be

necessary depending on local

environmental conditions such as

dirty atmospheres and the

conclusions reached in the risk

assessment. Cooling systems that

have a short operating period may

only need to be cleaned at the

beginning and end of that period. If

on inspection the system shows

signs of a significant build-up of

deposits or slime, then disinfection

and cleaning should

be carried out.

Technical

2. Warning

notices.

Post at approaches to cooling tower

and enclosure.

It is essential that anyone

approaching the cooling tower is

warned and notices must state:-

Restricted area - do not enter.

6M 2. Warning

notices.

Post at approaches to cooling tower

and enclosure.

It is essential that anyone

approaching the cooling tower is

warned and notices must state:-

Restricted area - do not enter.

6MOther

5. Electrical

equipment.

Ensure that all electrical equipment

is isolated except pumps.

Cooling tower fans and any adjacent

air intake fans must be isolated in

accordance with H&S requirements.


6M 5. Electrical

equipment.



Cooling tower fans and any adjacent

air intake fans must be isolated in



6MOther

9. Disinfection. Add sodium hypochlorite to

chlorinate, bring up concentration

to either 5 ppm or 30 ppm. (see

notes)

Any action taken must conform to

the requirements of CIBSE TM13 ,

HSE ACOP l8, 2001 and other H&S

regulations. At 5 ppm the system

should be run for at least six hours,

at 30 ppm, 2 hours. See item 10.

6M 9. Disinfection. Add sodium hypochlorite to

chlorinate, bring up concentration to

either 5 ppm or 30 ppm. (see

notes).

Any action taken must conform to

the requirements of CIBSE TM13 ,

HSE ACOP l8, 2000 and other H&S


shh/index.htm) regulations. At 5

ppm the system should be run for at

least six hours, at 30 ppm, 2 hours.

See item 10.

6MOther

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13. All surfaces. All accessible surfaces to be

cleaned with a wire brush. To

remove all deposits thoroughly

chemical cleaning may be

necessary.

Ensure all scale, rust and other

mineral and organic deposits are

removed. Any rust areas should be

treated and repainted.

6M 13. All surfaces. All accessible surfaces to be

cleaned with a wire brush. To

remove all deposits thoroughly

chemical cleaning may be

necessary.

Accessible areas of the tower and

its pack should be adequately

washed but cleaning methods that

create excessive spray, for example

high-pressure water jetting, should

be avoided. If this is not possible,

the operation should be carried out

when the building is unoccupied or,

in the case of permanently occupied

buildings, windows in the vicinity

should be closed, air inlets blanked

off and

the area that is being water-jetted

should be tented. The area should

be isolated and consideration

should also be given to other

occupied premises in the immediate

areas as well as members of the

public who may in the vicinity during

cleaning.

Ensure all scale, rust and other

mineral and organic deposits are

removed. Any rust areas should be

treated and repainted.

6MTechnical

17. Chlorination. Close drain valves, open water

supply, fill system and chlorinate to

5 ppm. Replace pump fuses, switch

on pumps and run system for six

hours.

Ensure that chlorination

concentration remains at 5 ppm

throughout 'run' period.

6M 17. Chlorination. Close drain valves, open water

supply, fill system and chlorinate to

5 ppm. Replace pump fuses,

switch on pumps and run system

for six hours. The use of a

biodispersant will enhance the

effectiveness of this chlorination. If

the system volume is greater than

5m3, the water should be

dechlorinated, drained, flushed and

refilled with fresh water and dosed

with the appropriate start-up level of

treatment chemicals, including the

biocides.

While the maintenance of a

continuous minimum residual of 5

mg/l of free chlorine for a minimum

period of 5 hours is considered the

best practice, if the downtime to

conduct such a lengthy operation is

not viable, some compromise may

be necessary. Under such

circumstances it may be acceptable

to shorten the pre- and

post-chlorination times and to

increase the free chlorine level, e.g.

50 mg/l for 1 hour or 25 mg/l for 2

hours. This should only be done if

the operators are trained in this

process because, at these levels,

there is a greater risk of damaging

the fabric of the system.

6MTechnical

19. Re-fill

system.

Note:- If chlorine concentration

exceeds 2 ppm prior to activating

water treatment regime, drain and

refill.

6M 19. Re-fill

system.

If chlorine concentration exceeds 2

ppm prior to activating water

treatment regime, drain and refill.

6MOther

20.Attenuators. Clean, derust and repaint as

required.

6M 20. Attenuators. Clean, derust and repaint as

required.

6MOther

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27. Bacterial

checks.

Take sample for TVC count. Note:- weekly dip slides will indicate

bacteria levels. A high bacterial level

does not necessarily mean the

Legionella bacteria are present.

6M 27. Bacterial

checks.

Take sample for TVC count. Weekly dip slides will indicate

bacteria levels. A high bacterial level

does not necessarily mean the

Legionella bacteria are present.

Bacterial checks should be

undertaken weekly.

3MOther

Tower HygieneAdded

Tower

Maintenance

Added

1. Fans and

Motors

Check the condition of the fan

motor through temperature or

vibration analysis and compare to

baseline values. Assure that all

bearings are lubricated per the

manufacture`s recommendation.

Check for excessive wear and

secure fastening. Aligning the

motor coupling allows for efficient

torque transfer.

1MAdded

2. Strainers Physically clean screen(s) of all

debris.

1WAdded

3. Drain and

Overflow

Check that drain and overflow are

clear from blockage.

1WAdded

4. Float Switches Operate switch manually to ensure

proper operation.

1WAdded

5. tower structure Check for excessive vibration in

motors, fans, and pumps. Check for

loose fill, connections, leaks, etc.

1WAdded

6. Water

Treatment

Check that water treatment

automatic dosing equipment is

functional.

For Further Guidance see Water

treatment SFG 65.

1WAdded

7. Test water

samples (Open

System)

Test for proper concentrations of

dissolved solids, and

microbiological quality of the pond

water by undertaking a dip slide

test. Adjust blowdown and

chemicals as necessary. Record

the result. Undertake additional

water quality tests such as pH,

conductivity and tests for hardness

salts as determined by risk

assessment.

See `Table 1 Typical on-site

monitoring checks recommended for

good operating practice` page 36 of

L8 3rd Edition 2000.

1WAdded

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8. Test water

samples (Closed

System)

Test for proper concentrations of

dissolved solids, and

microbiological quality of the pond

water by undertaking a dip slide

test. Adjust blowdown and

chemicals as necessary. Record

the result. Undertake additional

water quality tests such as pH,

conductivity and tests for hardness

salts as determined by risk

assessment.

See `Table 1 Typical on-site

monitoring checks recommended for

good operating practice` page 36 of

L8 3rd Edition 2000.

1MAdded

9. All internal

areas

Check internal surfaces for algae,

scale, rust and limescale

accumulation.

1MAdded

10. Drift

eliminators,

louvers, tubes and

fill

Look for proper positioning and

scale build up. Clean as needed

The frequency of the task can vary

depending on the water quality. The

Risk assessment may give greater

or lesser frequencies for this task.

1MAdded

11. Sparge Pipe Make sure water is flowing through

nozzles to ensure even distribution

over the fill.

1MAdded

12. Bearings Inspect bearings and drive belts for

wear. Adjust, repair, or replace as

necessary.

12MAdded

13. Motors Undertake annual maintenance.

For further Guidance see Motors

SFG 39-01.

12MAdded

Page 277 of 614

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DRY COOLERS30-03 30-03 DRY COOLERS


6. Electrical. Check for satisfactory operation of

local electrical isolation device

stoplock/isolator). Examine and







bonding is secure.

6MAdded

7. Insulation. Check condition. Repair and reseal

as necessary.

6MAdded

8. General

cleanliness.

Clean surfaces and components of

unit particularly fan impeller and

motor casing. Check and clean

surfaces of unit casing, check for

corrosion, repair and treat as found

necessary

Remove any dirt or rubbish from

vicinity of plant.

6MAdded

9. System

operation.


automatic sensors /detectors

(flow/temperature). Check for


plant. Ensure all devices are


Clean air inlet & discharge grilles.

Check all access doors for fit and

can be made secure. When shut,

ensure for air tight seal.

i.e. Start/stops and capacity

regulators should be in accordance

with externally applied control

systems if applicable.

6MAdded

1. Status. Isolate from electrical and other

services.

Isolate electrical supply in


6M 1. Status. Isolate from electrical and other

services.

Isolate electrical supply in

accordance with H&S


6MOther

2. Fans. See FANS.6M 2. Fans. Clean fan blades and lubricate if

required.

`Sealed for life` bearings should not

be serviced.

See Fans SFG 20.









instructions.

6MTechnical

3. Fins. 6M Deleted

Page 278 of 614

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a) external, Clean by blowing through with

compressed air or steam.

Note:- Any discharged refrigerant

(CFCs) must be recovered and NOT

released to atmosphere. Only a

REFCOM or other mandatory

scheme provider registered

engineer, must work on this

equipment.

6M 3a)Fins - external. Clean by blowing through with dry,

oxygen free, nitrogen.

Do not use refrigerant for cleaning

tubes use dry nitrogen or

compressed air. Sterilisation may be

required. Where Oxygen Free

Nitrogen is used, a Risk

Assessment must be carried out

prior to use and suitable training

given.

Any discharged refrigerant must be

recovered and not released to

atmosphere. Any persons working

on these systems must be

registered to an approved Certified

Scheme provider, in accordance

with the "F" Gas and Building

Regulations

6MTechnical

b) internal. Blow through with dry, oxygen free,

nitrogen.

6M 3b) Fins - internal. Blow through with dry, oxygen free,

nitrogen.


fins use dry nitrogen or compressed

air. Where Oxygen Free Nitrogen is

used, a Risk Assessment must be

carried out prior to use and suitable

training given.

6Mtechnical

Page 279 of 614

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30-04 ADIABATIC COOLERS


1. Ultra violet

generation unit.

Check system operational, clean

quartz glass sleeve if wipers are

fitted.

1MAdded

2. UV System

Cartridge.

Change. Frequency will depend upon water

quality.

1MAdded

3. Electrical

equipment.



Cooling fans and any adjacent air

intake fans must be isolated in


Refer to www.hse.gov.uk

(www.hse.gov.uk) for detail.

6MAdded

4. Fans. Clean fan blades and lubricate if

required.

`Sealed for life` bearings should not

be serviced.

See Fans SFG 20.









instructions.

6MAdded

5 Fins - external. Clean by initially blowing through

with dry, oxygen free or nitrogen.

All accessible surfaces to be

cleaned with a propriatry comb.

It may be necessary to carry out

additional cleaning or descaling to

remove all scale deposits

thoroughly. Chemical cleaning may

be necessary.








given.

Any discharged refrigerant must be


atmosphere. Engineers working on

these systems must belong to an

approved Certified Scheme

provider, in accordance with the "F"

Gas and Building Regulations

6MAdded

6. Water

Distribution

Check that the water distribution

system is free of dirt and debris. All

nozzles, troughs etc. need to be in

place and clean. In case of

contamination, clean the water

distribution system as per


Replace damaged or missing

nozzles, as well as any nozzles

which cannot be cleaned

6MAdded

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7. General

cleanliness.

Clean surfaces and components of

unit particularly fan impeller and

motor casing. Check and clean

surfaces of unit casing, check for

corrosion, repair and treat as found

necessary


vicinity of plant.

6MAdded

8. Coil vent. Check operation.6MAdded

9. Anti-vibration

mountings.

Check - visual condition, -

effectiveness.

There should be no transfer of

vibration or visible deterioration.

6MAdded

10 . Electrical. Check for satisfactory operation of









bonding is secure.

6MAdded


as necessary.

6MAdded

12. System

operation.










ensure for air tight seal.





6MAdded

13. Ultra violet

lamp.

Replace and note date in plant log. Replacement interval will depend

upon type of lamp, e.g. medium

pressure lamps - six months, low

pressure lamps - twelve months.

12MAdded

14. Electrical

safety.

Check security of connections and

condition of wiring.

12MAdded

15. Sediment

removal pre-filter.

Remove, clean and replace quartz

glass sleeve or thimble.

If feed water contains iron or organic

matter, quartz glass may require

more frequent cleaning.

24MAdded

Page 281 of 614

HIGH VOLTAGE WORKS

Page 282 of 614

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70-01 INTRODUCTORY PROCEDURES

Established safety rules should be issued or available to all persons operating or working on electrical

switchgear and control gear. Such persons should be familiar with the method of operation, and with

the safety precautions established for the premises. Instructions for the treatment of persons suffering

from electric shock should be displayed. A notice indicating the action to be taken in the event of fire

should be displayed. In premises subject to the requirements of the Factories Act 1961, a copy of the

relevant statutory regulations is to be displayed and any person working with electrical equipment

should have a copy of these regulations available to him. A diagram of the electrical apparatus and

relevant protection details of the installation should be available. Adequate quantities of safety locks

together with caution notices should be available for immediate use to facilitate safe working and

prevent conductors from being accidently or inadvertently electrically charged when persons are

working thereon. Danger notices to warn of the presence of live conductors should also be available

for immediate use. Essential labels should be legible, prominently displayed, made from durable

material and maintained up-to-date.

Emergency exits should be inspected prior to maintenance work on electrical equipment and should

be kept clear.

Because of the widely varying conditions of operation of individual installations, it is not possible to lay

down precise recommendations for the intervals between maintenance required under all

circumstances. However, the manufacturer should be requested to specify the minimum maintenance

frequency under specified conditions and give guidance on how this may vary under other conditions.

These intervals may vary greatly depending upon the design of the equipment, the duty that it is called

on to perform and the environment in which it is situated.

The frequency of maintenance will depend on a number of factors, the most important being the

conditions under which the equipment operates and the severity of duty. For continuously operating

plant it may be necessary to coordinate routine maintenance with the demands of the production

programme, but where there are regular periods during which the plant is shut down, maintenance

schedules may be arranged to coincide with those periods.

The intervals between maintenance operations may therefore be based on the number of operations

performed or on fixed time intervals, the preferred basis being determined by the electrical,

mechanical and environmental duties imposed. In practice, a

combination of these criteria may be used in the light of service experience with individual

installations. Whilst abnormally frequent operation may necessitate an increase in maintenance

frequency the converse is not necessarily true.

Added

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70-02 HV PACKAGED SUBSTATIONS

Please ensure that the introductory section of this task has been read and fully understood especially

in relation to the frequency of tasks being performed.

All works shall be in accordance with the code of practice for Maintenance of electrical switchgear and

control gear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping

electrical switchgear safe HSG230

Added


1. Non-intrusive

visual inspection

The general inspection check is

intended to ensure that the

switchgear is not under threat from

the environment in which it is

installed. It is intended that this

inspection can be performed with

the switchboard live although care

must be taken only to work on

accessible sides while the

equipment is live.

Carry out a general operating and

status check. Listen for any audible

discharge and check for any

unusual smells, checks for leakage

of coolants, lubricants, the status of

all instrumentation, and general

tidiness of the switchroom.

Inspect switchroom access and

surrounds (including fence and

external walls if outdoors) check for

signs of trespass and /or

interference.

Check for the presence and

legibility of warning notices.

Check fire fighting equipment.

Check signs of water

ingress/dampness in switchroom.

Check that no devices have tripped

and/or no fault passage indicators

are in the alarm condition.

Carry out thermal imaging of all

equipment and look for any local

high-resistant hot spots that may

show.

Should there be any signs of

malfunctioning, report back to the

client.

A check for any abnormal conditions

should be carried out immediately

on entering the substation and if any

danger is suspected then the

inspection should be aborted.

Typical warning signs are:

1) high temperature in switchroom;

2) presence of smoke;

3) smell of ‘hot’ substances (oil,

compound etc.);

4)audible discharges or arcing;

5)smell of ozone;

6)signs of leaked oil in vicinity of oil

circuit-breaker tank;

7)signs of fresh compound leaks;

8)distortion and evidence of sooting

on enclosures.

A limitation-of-access document

should be raised for any

non-intrusive visual-inspection

maintenance of the HV switchgear

and protection system.

6MAdded

2. Special tools Check that all special tools and

isolating equipment are serviceable

and in their correct locations.

6MAdded

Page 284 of 614

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3. Switchgear

general condition

Carry out an external visual

inspection of the switchgear

checking the general condition of

the exposed busbars and air break

switches (where present), check

general condition of the switchgear

checking for rust, oil leaks, oil level

gauge etc. Check for compound

leaks from cable boxes, busbar

chambers, band joints and end

caps. Check ammeters, voltmeters,

operation indicators, protection

equipment. Check labelling,

padlocks and key exchange

interlocks.

The same external inspection

should be carried out on associated

equipment, such as batteries and

chargers, control panels and other

ancillary equipment.

6MAdded

Page 285 of 614

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70-03 OIL SWITCHGEAR INCLUDING OIL CIRCUIT BREAKERS AND OIL

SWITCHES




control gear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping


Added


1. General

inspection










equipment is live.







checking for rust, oil leaks, oil level

gauge etc. Check for compound

leaks from cable boxes, busbar

chambers, band joints and end

caps. Check ammeters, voltmeters,

operation indicators, protection

equipment. Check labelling,

padlocks and key exchange

interlocks.










compound etc.);


5)smell of ozone;





on enclosures.






6MAdded

2. Ventilation Check ventilated equipment and

any restriction to the airflow

removed. In the case of mechanical

ventilation, the operation of

any airflow interlock should be

checked and corrected if

necessary.

Filters, where appropriate, should

be cleaned or renewed as

necessary.

12MAdded

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3. Protective

relays

Check protective relay settings.

inspection for condition, damage

and deterioration. For an

electromechanical type relay this

should include checks that: relay

movement runs freely; magnet

gaps and induction disc are clean;

contacts are not burnt or pitted

(refurbish as necessary); induction

disc resetting time

(electromechanical IDMT relays);

flag mechanisms and reset knobs

operate correctly; front cover glass

and seals are satisfactory; current

transformer shorting contacts

operate satisfactorily

Any maintenance on relays should

be carried out in accordance with

the manufacturer’s instructions and

should be incorporated in the

maintenance programme which

should include operational checking

of protective and interlock features.

12MAdded

4. Time limit fuses Inspect time limit fuses. Where

possible, actual timing periods

should be verified against the set

values and application

requirements, particularly if the

timing device has been dismantled

or replaced.

Such items should not be

dismantled for maintenance or

overhaul purposes unless this is

recommended in the manufacturer’s

instructions.

12MAdded

5. Shutters Inspect shutters for correct

operation.

12MAdded

6. Interlocks Inspect interlocks

Mechanical elements. All moving

parts should be clean, adequately

lubricated and be free to move as

intended. Any evidence of wear or

excessive free play should be

investigated and, if necessary,

reference made to the

manufacturer. All fixing devices

should be secure.

Electrical elements. If accessible

inspect control wiring for signs of

damage and check terminations for

tightness.

If in doubt concerning the condition

of the control wiring insulation it is

recommended that an insulation

resistance test be carried out.

12MAdded

7. Tank and tank

linings

On oil switches an inspection of the

tank and tank linings should be

carried out. This is not appropriate

at this frequency for Oil circuit

breakers.

12MAdded

8. Operational

check

Carry out an operational check12MAdded

9. Cleaning Clean as required.60MAdded

Page 287 of 614

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10. Closing and

trip mechanism

Check and lubricate circuit-breaker

isolating mechanism

60MAdded

11. Main and

arcing contacts

Examine main/arcing contacts for

excessive burning/damage

recondition or renew as required,

take account of manufacturer’s

requirements for different contact

construction and materials.

60MAdded

12. Auxiliary

contacts

Examine for wear (according to the

manufacturer’s handbook)

and for overheating, misalignment,

failure to disengage correctly

and other defects, and recondition

or renew as required.

Some auxiliary contacts are not

intended to be maintained. Such

items should not, therefore, be


overhaul purposes.

60MAdded

13. Secondary

wiring and fuses

Examine secondary wiring and

fuses. Carry out insulation

resistance test.

60MAdded

14. Insulation test Where practicable, porcelain and

moulded insulation should be

inspected for cracks and other

defects. Bonded and laminated

fibrous insulation and other organic

insulation should be inspected for

signs of tracking, treeing,

delamination and mechanical

damage.

Insulation resistance

measurements between poles and

between poles and earth are the

most suitable for insulation testing

under service conditions.

60MAdded

15. Earth

connections

Ensure that earthing connections

are mechanically and electrically

sound and that all contact screws

are tight and good contact is

maintained. Particular care should

be taken to reinstate fully all bolts

and screws, together with any

locking devices that might have

been disturbed during the

maintenance operation.

60MAdded

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16. Insulation oil Examine oil. If the oil is badly

discoloured or is excessively

contaminated by carbon particles in

suspension it may require

changing.

A representative sample of oil

should be taken and electric

strength, water content and acidity

tests which should be carried out in

accordance with BS EN 60422 with

suitable variation for high viscosity

oil. Oil that does not meet the

recommendations given in BS EN

60422 should be replaced with oil

that does. The oil level should be

maintained at the level specified by

the equipment manufacturer.

60MAdded

17. Heaters 60MAdded

18. Devices for arc

control

Examine for cracking or if eroded.

The free operation of the contactors

should be checked. Contacts

should not foul arc chutes or

barriers. The cleaning of barriers

should be carried out accordingly.

On older units some barriers contain

asbestos.

60MAdded

Page 289 of 614

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70-04 NON-OIL SWITCHGEAR




controlgear for voltages above 1 kV and up to and including 36 kV BS 6626:2010 and HSE keeping


Added


1. General

inspection










equipment is live.







checking for rust etc. Check for

compound leaks from cable boxes,

busbar chambers, band joints and

end caps. Check ammeters,

voltmeters, operation indicators,

protection equipment. Check

labelling, padlocks and key

exchange interlocks.










compound etc.);


5)smell of ozone;





on enclosures.






6MAdded







necessary.



necessary.

12MAdded

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Sulphur

hexafluoride

switchgear -

inspection

Sulphur hexafluoride switchgear is

designed to be low maintenance.

Maintenance using a time-interval

approach, based on manufacturer’s

recommendations, may be applied

to such switchgear.

Sulphur hexafluoride (SF6 ) is listed

as a fluorinated greenhouse gas in

European Union Regulation EC

842/2006 [9] (on certain fluorinated

greenhouse gases), the

requirements of which are referred

to in the Fluorinated Greenhouse

Gases Regulations 2009. As such,

SF6 is subject to strict requirements

governing its use, which are

intended to prevent and minimize

any release into the atmosphere.

EC Regulation 305/2008 [10], which

is also referred to in the Fluorinated

Greenhouse Gases Regulations

2009, requires individuals who carry

out recovery of SF6 gas from high

voltage switchgear to be

appropriately trained and assessed

and to hold a written qualification

issued by a certification body.

Added

3. General

inspection In

addition to item 1.

above check

pressure gauge.

Check the gas pressure gauge

should be checked, a pungent

smell indicates gas leakage.

12MAdded

4. Mechanisms inspection, adjustment and

lubrication of mechanisms

(including shutters where

appropriate)

60MAdded

5. Contacts Examine of primary isolating

contacts for damage, burning,

corrosion - cleaning and

refurbishing (as necessary)

60MAdded

6. Circuit Breaker

isolating

mechanism


isolating mechanism

60MAdded

7. Indicators and

interlocks

Inspect interlocks









should be secure.




tightness.





60MAdded

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8. Cable

termination

chambers

Examine inside of cable termination

chambers and other chambers as

appropriate, removal of surface

contamination from accessible solid

insulation (where applicable)

60MAdded

9. Secondary

injection test

Secondary injection testing on

circuit-breaker protection system

(or, if this is not scheduled, carry

out manual trip-test);

60MAdded

10. Auxiliary

contacts











overhaul purposes.

60MAdded

11. Secondary

wiring and fuses


fuses. Carry out insulation

resistance test.

60MAdded

Vacuum

Switchgear

Vacuum switchgear is designed to

be low maintenance. Maintenance

using a time-interval approach,

based on manufacturer’s


to such switchgear.

A vacuum interrupter is a sealed unit

on which no internal maintenance

can be carried out. Contact wear is

not normally a problem, however

circuit breakers often have a method

for indicating contact erosion.

The minimum vacuum life of the

vacuum interrupter can be expected

to be stated by the manufacturer as

this is specified in BS EN 62271-1

and is from the date of seal-off not

the date of start of service; however,

experience indicates that the actual

lifetime is well in excess of the

stated minimum value. During this

period, vacuum integrity can be

confirmed by methods

recommended by the manufacturer.

These normally consist of voltage

withstand tests which can confirm

the loss of vacuum but cannot

predict future life expectancy. If a

voltage withstand test confirms loss

of vacuum it is essential that the unit

is replaced.

Added

12. General

inspection - Carry

out item 1. above

Carry out general inspection.12MAdded

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13. Voltage

Transformer

Examine and check voltage

transformer (as required)

Steps should be taken to ensure

that a voltage transformer is dead

and isolated and discharged to earth

before it is examined. Where

protective fuses are fitted, particular

care should be taken to ensure

that the voltage transformer is

discharged to earth.

60MAdded

14. Vacuum

Integrity test

Check the vacuum integrity by a

high-voltage pressure test

With vacuum switchgear, X-rays

may be generated when the open

contact gap is stressed at

high-voltage. There are no harmful

emissions at normal service voltage

but if a high-voltage pressure test is

carried out with the switchgear in an

open position then X-rays may be

generated. Guidance should be

sought from the manufacturer on

the maximum voltage that can be

applied to ensure that the maximum

level of radiation generated is less

than that permitted for unclassified

workers in the Ionising Radiation

(Sealed Sources) Regulations 1969.

60MAdded




appropriate)

60MAdded

16. Contacts Examine of primary isolating

contacts for damage, burning,

corrosion - cleaning and

refurbishing (as necessary).

Carry out measurement of contact

wear where a measurement

method is available

60MAdded

17. Circuit Breaker

isolating

mechanism


isolating mechanism

60MAdded

18. Indicators and

interlocks

Inspect interlocks









should be secure.




tightness.





60MAdded

Page 293 of 614

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19. Cable

termination

chambers






60MAdded

20. Secondary

injection test





60MAdded

21. Auxiliary

contacts











overhaul purposes.

60MAdded

22. Secondary

wiring and fuses


fuses.

60MAdded

Air-Break

Switchgear

Maintenance using a time-interval

approach, based on manufacturer’s


to such switchgear.

Added

23. General

inspection - Carry

out item 1. above

Carry out general inspection.12MAdded

24. Contacts Examine main/arcing contacts for

excessive burning/damage

recondition or renew as required,

take account of manufacturer’s

requirements for different contact

construction and materials.

60MAdded

25. Contact

springs

check/adjust spring contact force

and contact alignment as required

60MAdded

26. Arc chutes Remove, examine and clean the

arc chutes - renew if damaged or

eroded

60MAdded




appropriate)

60MAdded

28. Circuit Breaker

isolating

mechanism


isolating mechanism

60MAdded

Page 294 of 614

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29. Indicators and

interlocks

Inspect interlocks









should be secure.




tightness.





60MAdded

30. Cable

termination

chambers






60MAdded

31. Secondary

injection test





60MAdded

32. Auxiliary

contacts











overhaul purposes.

60MAdded

33. Secondary

wiring and fuses


fuses.

60MAdded

34. Voltage

Transformer

Examine and check voltage

transformer (as required)

Steps should be taken to ensure

that a voltage transformer is dead

and isolated and discharged to earth

before it is examined. Where

protective fuses are fitted, particular

care should be taken to ensure

that the voltage transformer is

discharged to earth.

60MAdded

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70-05 VACUUM INDOOR SWITCHGEAR






If equipment is removed from service, before it is re-used perform the following tests

- Main and Earth circuit resistance

- Power frequency

- Protection system

Added


1. General

inspection










equipment is live.







checking for rust etc. Check for

compound leaks from cable boxes,

busbar chambers, band joints and

end caps. Check ammeters,

voltmeters, operation indicators,

protection equipment. Check

labelling, padlocks and key

exchange interlocks.










compound etc.);


5)smell of ozone;





on enclosures.






6MAdded







necessary.



necessary.

12MAdded

Page 296 of 614

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3. Housing Check all external fixings, labels

and earth connections are present

and tight. Check inside the MV

cable box, busbar system LV

cabinet and pilot cable box for

heavy deposits of dust, ingress of

water or contamination by animal or

plant life. Clean the units thoroughly

and touch up paint work as

necessary.

120MAdded

4. Protection

system

Check that the protection settings

are correct on the relay.

perform a primary or secondary

current injection test to prove

that the protection circuit is OK and

that the tripping mechanism

is OK. (Primary injection is the

preferred method as it proves

the CT’s as well, but it will need the

cables removing so may be

inconvenient)

120MAdded

5. Voltage

Presence Indicator

System [VPIS]

Before the switchgear is isolated

ensure that all three phases are

indicating correctly.

The manufacturers life expectancy

of a VPIS device is between 10 & 20

years, therefore the VPIS device

should be replaced at each major

maintenance interval.

120MAdded

6. Voltage

transformer

Before de-energising the

switchboard measure the

secondary

voltage of the VTs. Check continuity

of VT fuses. For unscreened VTs

clean down the external surface of

the insulation with Isopropanol and

lint free cloths to remove any

excess dust/debris. check the

external surface for signs of partial

discharges.

120MAdded

7. Cable boxes Perform a visual inspection of the

cable termination, looking in

particular for signs of partial

discharges, black or white surface

contamination or over heating. With

Isopropanol alcohol and a lint free

cloth clean down the surface of the

cable termination to remove any

contamination from the surface.

With a vacuum cleaner remove any

excess dust from inside the box

then wipe down the inside surface

of the box with Isopropanol alcohol.

Ensure all seals and fixings are

present. Ensure cable earth is

securely connected back to the

switchgear’s main earth bar.

Added

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8. Busbar

chamber

perform a visual inspection of the

busbars and busbar boots,

looking in particular for signs of

mechanical damage, partial

discharges or over heating. ensure

that the busbar is assembled

correctly and correctly torqued. with

Isopropanol alcohol and a lint free

cloth clean down the surface of the

busbars and the insulated busbar

boots to remove any contamination

from the surface. with a vacuum

cleaner remove any excess dust

from inside the busbar chamber

then wipe down the inside surface

of the chamber with Isopropanol

alcohol. Ensure all seals and fixings

are present.

120MAdded

9. Vacuum circuit

breakers

Perform a resistance test across

the closed circuit breaker

contacts. Perform either a 20kV

Accepted or 25kV DC pressure test

across the open contacts. Ensure

that the pas pressure is in the

green zone of the pressure gauge.

120MAdded

10. Cable test

points and earth

circuits

Open the cable test points and

ensure that the moving earth bars

and the fixed contacts are fixed

securely, clean, free of corrosion

and that the contact surfaces are

lubricated. Perform a

resistance/continuity test from the

switchgears main earth bar back to

the substations main earth point.

120MAdded

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70-06 FLUID FILLED TRANSFORMER

The frequency of maintenance inspection should be determined

by factors such as transformer size, application and importance of service continuity as experience

dictates. Also, local climatic and atmospheric conditions will influence the inspection schedule.

Inspection and some minor maintenance, such as on paintwork, may be carried out with the

transformer live, however, the policy to be followed in making equipment available for maintenance

should always be that it should be isolated, proved dead where possible and immediately earthed. A

"permit to work" should be provided to ensure safety to personnel and equipment.

The ingress of moisture and dirt into the transformer can cause malfunction and danger. Care should

be taken to prevent such ingress whilst work is in progress, and covers should be replaced as soon as

access to the transformer tank / disconnection chambers / termination boxes is no longer required.

Before final closure of any compartment is effected, a careful inspection should be carried out to make

sure no foreign matter or loose material is present.

Before work is undertaken in any chamber containing high / low voltage conductors, tests using

suitable voltage indicators should be carried out. These should include tests between each phase and

earth to ensure all conductors are dead.

Added


1. Non-intrusive

visual inspection










equipment is live.














show.



client.










compound etc.);


5)smell of ozone;





on enclosures.






6MAdded

2. Silica Gel

Dryers

If appropriate inspect silica gel

dryers to ensure that the desiccant

is still active.

If the unit indicates that saturation

has been reached change the

desiccant or cartridge as required.

6MAdded

3. Fluid Inspect fluid level.12MAdded

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4. Paintwork Inspect paintwork condition and

carry out remedial painting as

required.

A zinc based primer should then be

applied followed

by a quick drying top coat of paint.

18MAdded

5. Bolted

connections and

fixings

Torque check all bolted connections

and fixings in accordance with the

manufacturers settings.

Thermal cycling and mechanical

forces due to load, wind or local

vibration and shock can result in

relaxation of gaskets and small oil

leaks. Fixings and fasteners should

therefore be periodically checked.

18MAdded

6. Earth Test earth connection integrity.

Earth loop impedance

measurements may be carried out.

18MAdded

7. Fluid Inspect fluid level and take sample

for analysis.

Test dielectric strength, moisture

content &

gas analysis of insulating fluid.

Care should be taken when

obtaining a sample as the head of

fluid above the sample valve will

force the fluid out rapidly. An

equivalent amount of clean new fluid

should be added to the transformer

through its bolted filler cap / cover

positioned on top of the transformer

cover

Renewal / change of dielectric fluid

as required and indicated by

manufacturers recommendation.

It is not a usual requirement to take

fluid samples from an hermetically

sealed transformer, as they are

sealed from the environment, as

such preventing ingress of

contamination to the dielectric fluid.

Samples should only be taken to

establish the condition of fluid after

overload or fault and normally by the

manufacturer.

18MAdded

8. Insulation test Where practicable, porcelain and

moulded insulation should be

inspected for cracks and other

defects. Bonded and laminated

fibrous insulation and other organic

insulation should be inspected for

signs of tracking, treeing,

delamination and mechanical

damage.

Insulation resistance

measurements between poles and

between poles and earth are the

most suitable for insulation testing

under service conditions. Test

insulation resistance measurement

by Megger

18MAdded

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9. Dehydrating

breather

Where fitted inspect dehydrating

breather.

18MAdded

10. Liquid

temperature

indicator

Where fitted inspect and test liquid

temperature indicator.

18MAdded

11. Winding

temperature

indicator

Where fitted inspect and test

winding temperature indicator.

18MAdded

12. Pressure relief

device

Where fitted inspect pressure relief

device.

No maintenance is necessary.18MAdded

13. Gas & Oil

actuated relay

Where fitted inspect gas & oil

actuated relay.

18MAdded

14. Magnetic liquid

level indicator

Where fitted inspect magnetic liquid

level indicator.

18MAdded

15. Vacuum /

pressure gauge

Where fitted inspect vacuum /

pressure gauge.

No maintenance is necessary.18MAdded

16. Off circuit

tapping switch

Check off circuit tapping switch

operation.

18MAdded

17. Ventilation Carry out ventilation check. Checks

should me made that the ventilation

provided for the transformer is

sufficient (e.g. substation ventilation

grills are clean and clear of

obstructions).

The substation ambient temperature

should be checked to ensure it is

defined by BS EN 60076 and IEC

76.

18MAdded

18. Harmonic load Carry out harmonic load test.18MAdded

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70-07 CAST RESIN TRANSFORMER






A check for any abnormal conditions should be carried out immediately on entering the substation and

if any danger is suspected then the inspection should be aborted. Typical warning signs are:



3) smell of ‘hot’ substances (oil, compound etc.);


5)smell of ozone;

6)signs of leaked oil in vicinity of oil circuit-breaker tank;


8)distortion and evidence of sooting on enclosures.

A limitation-of-access document should be raised for any non-intrusive visual-inspection maintenance

of the HV switchgear and protection system.

Added


1. Non-intrusive

visual inspection The general inspection check is









equipment is live.














show.



client.

6MAdded

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2. Paintwork Inspect paintwork condition and

carry out remedial painting as

required.

A zinc based primer should then be

applied followed

by a quick drying top coat of paint.

12MAdded

3. Bolted

connections and

fixings

Torque check all bolted connections

and fixings in accordance with the

manufacturers settings.

Thermal cycling and mechanical

forces due to load, wind or local

vibration and shock can result in

relaxation of gaskets and small oil

leaks. Fixings and fasteners should

therefore be periodically checked.

12MAdded

4. Clean Vacuum clean, and blow places

which are less accessible, with dry

compressed air or nitrogen.

Clean lead or cable supports, tap

changers, bushings and other

insulating surfaces using brush or

wiping with lint free cloth.

The frequency of cleaning will

depend on environmental

conditions. In case of fast dust

deposits, increase the yearly

frequency, and if necessary filter the

air cooling flow.

In the case of greasy dust deposits,

use only methylated spirit to clean

the resin surfaces.

12MAdded

5. Insulation

Power Factor Test

Using capacitance bridge

instrument, check insulation power

factor of:

i) Primary/Secondary and Earth.

ii) Secondary/Primary and Earth.

Record capacitance values,

dissipation factor and insulation

power factor. Compare field test

results to manufacturer`s factory

test results and to previous

maintenance test results.

12MAdded

6. Ratio Test Carry out ratio test of windings in all

tap positions to ensure accuracy to

within 0.001 percent. Compare test

data to factory test results.

12MAdded

7. Insulation

Resistance

Use megger to measure resistance

between:

i) Primary and Secondary.

ii) Primary/Secondary and Earth.

Iii) Secondary/Primary and Earth.

Compare test results to factory test

data and to previous maintenance

test results.

12MAdded

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8. Core Earth Test Remove earth strap between

laminated core and ground. Megger

test using 250 volt megger (or as

recommended by manufacturer)

between core and ground to ensure

no other grounds exist between

core and ground. Compare values

to factory test values and to

previous maintenance test results.

Reconnect ground strap.

12MAdded

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70-08 RING MAIN UNIT






Sulphur hexafluoride (SF6 ) is listed as a fluorinated greenhouse gas in European Union Regulation

EC 842/2006 [9] (on certain fluorinated greenhouse gases), the requirements of which are referred to

in the Fluorinated Greenhouse Gases Regulations 2009. As such, SF6 is subject to strict

requirements governing its use, which are intended to prevent and minimize any release into the

atmosphere.

EC Regulation 305/2008 [10], which is also referred to in the Fluorinated Greenhouse Gases

Regulations 2009, requires individuals who carry out recovery of SF6 gas from high voltage

switchgear to be appropriately trained and assessed and to hold a written qualification issued by a

certification body.

Added


1. Non-intrusive

visual inspection










equipment is live.














show.



client.


should be carried out and if any







compound etc.);


5)smell of ozone;





on enclosures.






6MAdded

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2. Housing exterior Check all external fixings, labels

and earth connections are present

and tight. Check inside the main

door (if fitted) and pilot cable box

for heavy deposits of dust, ingress

of water or contamination by animal

or plant life. Check condition of the

main door seal.

Where Sulphur hexafluoride [SF6]

gas - Check that the gas indicator is

reading in the green zone [if fitted].

Clean the units thoroughly and

touch up paint work as necessary.

24MAdded

3. Housing interior Open the main and pilot cable box

door. Where Sulphur hexafluoride

[SF6] gas - Check that the gas

indicator is in the green zone and

the protector cap is fitted over the

gas filler valve. For circuit breaker

panels check the electrical

protection system - refer to

manufacturers commissioning

instructions.

Check the operation of the unit and

all mechanical interlocks. Clean the

unit thoroughly.

In the event of a Sulphur

hexafluoride [SF6] gas leak contact

the manufacturers service team

immediately.

60MAdded

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70-09 HV SWITCHPANEL






Added


1. Non-intrusive

visual inspection










equipment is live.














show.



client.

A check for any abnormal

conditions should be carried out

immediately on entering the

substation and if any danger is

suspected then the inspection

should be aborted. Typical warning

signs are:




compound etc.);


5)smell of ozone;





on enclosures.






6MAdded

2. Feeder circuit

breakers

General inspection and operation,

cleaning of insulation if necessary.

Inspection, cleaning and

de-greasing of isolating contacts.

12MAdded

3. Incoming

isolators

Clean and de-grease the isolator

locks/hooks rotating points and the

external part of shutter. Check that

the cleaned parts rotate correctly

and lubricate in accordance with


Check mechanical operation of the

operating mechanism.

12MAdded

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4. Earthing switch Clean earthing switch and

de-greasing the friction points at

roller level and interlock level.

Lubricate friction points in


recommendations. Check

mechanical operation and function.

12MAdded

5. Earth bar Check earth bar for security and

damage to insulators.

12MAdded

6. Testing Carry out full testing and inspection

in accordance and Safety in

electrical testing at work INDG 354

and EIS 37

12MAdded

Page 308 of 614

HOT & COLD WATER SERVICES

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Hot and Cold Water Services including Drinking Water

This section covers the maintenance procedures associated with the provision of hot and cold water.







Part 1 being regulatory and Part 2 guidance. If you are prosecuted for breach of health & safety law

and it is proved that you did not follow the relevant provisions of the code, you will need to show that

you have complied with the law in some other way or a court will find you at fault. Health and safety

inspectors seek to secure compliance with the law and may refer to the L8 as illustrating good

practise. It is therefore important to comply with it.

In healthcare premises, HTM 04 part A & B now supersede the old HTM 2027 and HTM2040 has

been revised in line with changes to relevant regulations, standards and other guidance and also

technical developments including the ACOP L8. For this reason in healthcare establishments HTM 04

is to be followed. This will automatically satisfy the requirements of L8.

The Standard Maintenance Specifications should be adequate for the majority of well engineered low

risk systems outside of healthcare premises conforming to the requirements of ACOP L8,2001.

Additional work may be required for less ideal systems and these should be specified as part of the

prevention/control scheme.




For guidance the following statement is taken from the ACOP L8

1 This Approved Code of Practice gives practical advice on the requirements of the Health and Safety

at Work etc Act 1974 (HSWA) and the Control of Substances Hazardous to Health Regulations 2002

(COSHH) concerning the risk from exposure to legionella bacteria. In particular it gives guidance on

sections 2, 3, 4 and a (as amended by the Consumer Protection Act 1987) of HSWA and regulations

6, 7, 8, 9 and 12 of COSHH. The Code also gives guidance on compliance with the relevant pans of

the Management of Health and Safety at Work Regulations 1999 (MHSWR).

2 This publication replaces two separate documents: the 1995 Approved Code of Practice and the

technical guidance, HSG7O. This has allowed information to be consolidated, with the aim of making

it easier to read and understand the duties under the law. Since the last revision, the Health and

Safety Executive (HSE) and others have funded research to assess the efficacy of new and

alternative control strategies. This current document incorporates the findings of that research and

explains how such strategies can be used safely and effectively .

3 This Code applies to the risk from legionella bacteria (the causative agent of legionellosis including

Legionnaires’ disease) in circumstances where the Health and Safety at Work Act 1974 applies.

4 To comply with their legal duties, employers and those with responsibilities for the control of

premises must:

(a) identify and assess sources or risk— this includes checking whether conditions are present which

will encourage bacteria to mulitply, e.g is the water temperature between 20—45ºC; there is a means

of creating and disseminating breathable droplets, e.g the aerosol created by a shower or cooling

tower and if there are susceptible people who may he exposed to the contaminated aerosols (see

paragraphs 23-38);

(b) prepare a scheme for preventing or controlling the risk;

(c) implement, manage and monitor precautions - if control measures are to remain effective, then

regular monitoring of the systems and the control measures is essential (see paragraphs 61-05).

Monitoring of general bacterial numbers can indicate whether microbiological control is being achieved

(see paragraphs 124-129 and 183-184). Sampling for legionella is another means of checking that a

system is under control (see paragraphs 130-l31 and 185-189);

(d) keep records of the precautions; and

Hot and Cold Water Services including Drinking Water

This section covers the maintenance procedures associated with the provision of hot and cold water.







guidance.

In healthcare premises HTM 04 part A & B now supersedes the old HTM 2027 and HTM2040 and has

been revised in line with changes to relevant regulations, standards and other guidance, and also

technical developments including the ACOP L8. For this reason in healthcare establishments HTM 04

is to be followed. This will automatically satisfy the requirements of L8.

The Standard Maintenance Specifications should be adequate for the majority of well engineered low

risk systems outside of healthcare premises conforming to the requirements of ACOP L8,2000.

Additional work may be required for less ideal systems and these should be specified as part of the

prevention/control scheme.




For guidance the following statements are taken from the ACOP L8

1. This Approved Code of Practice gives practical advice on the requirements of the Health and Safety

at Work etc. Act 1974 (HSWA) and the Control of Substances Hazardous to Health Regulations 1999

(COSHH) concerning the risk from exposure to legionella bacteria. In particular it gives guidance on

sections 2, 3, 4 and (as amended by the Consumer Protection Act 1987) of HSWA and regulations 6,

7, 8, 9 and 12 of COSHH. The Code also gives guidance on compliance with the relevant parts of the

Management of Health and Safety at Work Regulations 1999 (MHSWR).

2. This publication replaces two separate documents: the 1995 Approved Code of Practice and the

technical guidance, HSG7O. This has allowed information to be consolidated, with the aim of making

it easier to read and understand the duties under the law. Since the last revision, the Health and

Safety Executive (HSE) and others have funded research to assess the efficacy of new and

alternative control strategies. This new document incorporates the findings of that research and

explains how such strategies can be used safely and effectively .

3. This Code applies to the risk from legionella bacteria (the causative agent of legionellosis including

Legionnaires’ disease) in circumstances where the Health and Safety at Work etc. Act 1974 applies.

4. To comply with their legal duties, employers and those with responsibilities for the control of

premises should:

(a) identify and assess sources or risk— this includes checking whether conditions are present which

will encourage bacteria to multiply, e.g. is the water temperature between 20—45oC; there is a means

of creating and disseminating breathable droplets, e.g. the aerosol created by a shower or cooling

tower; and if there are susceptible people who may he exposed to the contaminated aerosols (see

Technical

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(e) appoint a person to be managerially responsible.

5 The Code and guidance also set out the responsibilities of suppliers of services such as water

treatment and maintenance as well as the responsibilities of manufacturers, importers, suppliers and

installers.

The following conditions can all increase the rate of growth of Legionella:

a) Water temperatures in the range 20-45º C,

b) Presence of sediment, sludge, scale or organic material,

c) Certain non approved construction materials,

d) Rust

e) Commonly encountered water organisms such as algae, amoeba, slimes and biofilms.

Metering

Metering of potable water supplies by the Statutory Water Undertakings is being introduced more

widely and is now considered for all new premises. Metering of potable water supplies is becoming

more common practice and the need to the maintenance of such meters.

Pressure Systems and Transportable Gas Containers Regulations 1989

A written scheme of examination drawn up, by a ‘competent person’, must be in place for all plant and

equipment which is subject to these regulations.

Most pressure systems carrying a relevant fluid will require written schemes and regular inspection.

paragraphs 23-38);

(b) prepare a scheme for preventing or controlling the risk;

(c) implement, manage and monitor precautions - if control measures are to remain effective, then

regular monitoring of the systems and the control measures is essential (see paragraphs 61-05).

Monitoring of general bacterial numbers can indicate whether microbiological control is being achieved

(see paragraphs 124-129 and 183-184). Sampling for legionella is another means of checking that a

system is under control (see paragraphs 130- 131 and 185- 189);

(d) keep records of the precautions; and

(e) appoint a person to be managerially responsible.

5. The Code and guidance also set out the responsibilities of suppliers of services such as water

treatment and maintenance as well as the responsibilities of manufacturers, importers, suppliers and

installers.

The following conditions can all increase the rate of growth of Legionella:

a) Water temperatures in the range 20-45o C,

b) Presence of sediment, sludge, scale or organic material,

c) Certain non approved construction materials,

d) Rust

e) Commonly encountered water organisms such as algae, amoeba, slimes and biofilms.

Metering

Metering of potable water supplies by the Statutory Water Undertakings is being introduced more

widely and is now required for all new premise and consideration will have to be given to the

maintenance of such meters.

Risk assessment - a site survey of all the water systems should be carried out and should include an

asset register of all associated plant, pumps, strainers and other relevant items. This should include

an up-to-date drawing/diagram showing the layout of the plant or system, including parts temporarily

out of use. The assessment should be reviewed regularly (at least every two years) and, whenever

there is reason to suspect that it is no longer valid. An indication of when to review the assessment

and what needs to be reviewed should be recorded. This may result from, for example:

(a) changes to the water system or its use;

(b) changes to the use of the building in which the water system is installed;

(c) the availability of new information about risks or control measures;

(d) the results of checks indicating that control measures are no longer effective ;

(e) a case of Legionnaires’ disease/legionellosis is associated with the system.

Calorifier maintenance [where appropriate] come under The Pressure Systems Safety Regulations

2000

A written scheme of examination drawn up, by a ‘competent person’, must be in place for all plant and

equipment which is subject to these regulations.


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HOT WATER SUPPLY

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The provision of hot water entails two important safeguards, namely the avoidance of scalding and the

prevention of legionellosis or Legionnaires' disease. It is imperative that the client is aware of these

problems and that steps are taken both by the site staff and the maintenance contractor to prevent

their occurrence. Specific details relating to the risk of Legionellosis are given in the Health and Safety

ACOP L8,2001 ,CIBSE publication TM13 2002, HTM 04 Part A & B and the 5 page guidance from the

Water Management Society named “How to keep out of court”

Operating Temperature

ACOP L8,2001 recommends that water services should operate at temperatures that prevent the

proliferation of legionella, that is:

a) hot water storage (calorifiers), 60°C,

b) hot water distribution, at least 50°C attainable at the taps within one minute of running, health care

under HTM 04 Part B states 55°C

c) cold water storage temperature, 20°C or below.

Client's staff should check temperatures monthly as required by ACOP L8,2001 and HTM 04 Part B

It has been common practice to operate hot water systems in the range 45° to 50°C. At those

temperatures there is little risk of scalding, but there is a risk of legionellosis. The bacteria remains

active up to approximately 50°C and is only effectively killed at temperatures approaching 60°C.

At water temperatures above 50°C there is a risk of scalding, which increases with temperature and

time of contact. In premises used by persons at risk, e.g. old people, sick persons, and children, fail

safe thermostatically controlled mixing valves must be used. The HSE circular - Controlling Legionella

in Nursing and Residential Care Homes INDG 253, 1997 suggests that temperatures should be

limited to 41 ± 2°C. This should be checked by client's staff at least monthly. NHS DO8 applies

Where the water temperatures advocated in ACOP L8, 2001 cannot be maintained, alternative control

measures will need to be considered. These could include ongoing low level disinfection using

Chlorine Dioxide or Silver Copper Ions. These systems are briefly explained in L8 & HTM 04 part A

Chapter 15 page 41

Distribution Pipework

The pipework system should be free of any points where dirt, slime or sediment may accumulate to

ensure that there are no deposits, which could provide a source of nutriment to sustain the legionella

bacteria. Where this is not possible the system should be continually disinfected as in the previous

paragraph. This also applies where pipe replacement or alterations take place and disinfection

procedure must be strictly followed.

Hot Water Supply

Pressurised Systems

It should be recognised that danger can arise during the maintenance of pressurised systems if steps

are not taken to relieve any residual pressure before opening valves, joints or vessels to atmospheric

pressure.

Air Venting

Air is a poor conductor of heat and it should be eliminated from primary hot water systems using the

air vents on the system. These are to be found at the top of the towel rails and in pressurised systems

where automatic air venting valves are provided. It is essential that these are checked and maintained

at the proper frequencies. Under no circumstances should air be allowed to disturb the system in

domestic services as this will disturb natural biofilm and lead to providing a food source for the

Legionella bacteria. Also towel rails are not permitted on domestic hot water systems.

Allocated times on Legionella control are not accurate as times are dependant on access and

numbers of systems to be checked. The assessment should be detailed enough to give reasonable

information to estimate times of maintenance.

The provision of hot water entails two important safeguards, namely the avoidance of scalding and the

prevention of legionellosis or Legionnaires` disease. It is imperative that the client is aware of these

problems and that steps are taken both by the site staff and the maintenance provider to prevent their

occurrence. Specific details relating to the risk of Legionellosis are given in the Health and Safety

ACOP L8,2000 ,CIBSE publication TM13 2002, HTM 04 Part A & B.

Operating Temperature

ACOP L8,2000 recommends that water services should operate at temperatures that prevent the

proliferation of legionella, that is:

a) hot water storage (calorifiers), 60°C,

b) hot water distribution, at least 50°C attainable at the taps within one minute of running, health care

under HTM 04 Part B states 55°C

c) cold water storage temperature, 20°C or below.

client`s staff should check temperatures monthly as required by ACOP L8,2000 and HTM 04 Part B

It has been common practice to operate hot water systems in the range 45° to 50°C. At those

temperatures there is little risk of scalding, but there is a risk of legionellosis. The bacteria remains

active up to approximately 50°C and is only effectively killed at temperatures approaching 60°C.

At water temperatures above 50°C there is a risk of scalding, which increases with temperature and

time of contact. In premises used by persons at risk, e.g. old people, sick persons, people with

reduced mental capacity, reduced mobility, anyone with sensory impairment and children, fail safe

thermostatically controlled mixing valves must be used. Department of Health, HTM 04-01 Part A sets

out the safe water temperatures and appropriate delivery devices (TMV`s) over a range of

areas/activities. HS(G)220 Health and safety in care homes - issued 12/01 (file 357) recommends that

where vulnerable people are at risk from scalding during whole body immersion, water temperatures

do not exceed 44°C. This should be checked by client`s staff at least monthly. NHS MES (Model

Engineering Specification) D 08 applies.

Where the water temperatures advocated in ACOP L8, 2000 cannot be maintained, alternative control

measures will need to be considered. These could include ongoing low level disinfection using

Chlorine Dioxide or Silver Copper Ions. These systems are briefly explained in L8 & HTM 04 part A.

Distribution Pipework

The pipework system should be free of any points where dirt, slime or sediment may accumulate to

ensure that there are no deposits, which could provide a source of nutriment to sustain the legionella

bacteria. Where this is not possible the system should be continually disinfected as in the previous

paragraph. This also applies where pipe replacement or alterations take place and disinfection

procedure must be strictly followed. The pipe work should be well insulated to prevent heat loss

between calorifier and outlet.

Hot Water Supply

Pressurised Systems

It should be recognised that danger can arise during the maintenance of pressurised systems if steps

are not taken to relieve any residual pressure before opening valves, joints or vessels to atmospheric

Other

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pressure.

Air Venting

Air is a poor conductor of heat and it should be eliminated from primary hot water systems using the

air vents on the system. These are to be found at the top of the towel rails and in pressurised systems

where automatic air venting valves are provided. It is essential that these are checked and maintained

at the proper frequencies. Under no circumstances should air be allowed to disturb the system in

domestic services as this will disturb natural biofilm and lead to providing a food source for the

Legionella bacteria. Also towel rails are not permitted on domestic hot water systems.

Allocated times on Legionella control are not accurate as times are dependant on access and

numbers of systems to be checked. The assessment should be detailed enough to give reasonable

information to estimate times of maintenance.Technical

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HOT WATER SERVICES general32-02 32-02 HOT WATER SERVICES general

Note: A log book describing these services should be maintained and details entered about the

various maintenance activities and results of all the tests.

A log book describing these services should be maintained and details entered about the various

maintenance activities and results of all the tests.

Other


2. Cold water

temperature (at

outlet of cistern or

tank and farthest

outlet from

cistern).

Monitor to ensure compliance with

ACOP L8, 2001 & HTM 04 Part B

requirements.

Responsibility for this test should be

agreed with client. Advise client if

temperature outside ACOP L8, 2001

requirements for any remedial work

to be put in hand.

1M 2. Cold water

temperature (at

outlet of cistern or

tank and farthest

outlet from

cistern).


ACOP L8, 2000 (www.hse.gov.uk)

& HTM 04 Part B requirements.





to be put in hand.

1MOther

3. Hot water

temperature (at

outlet of calorifier).


ACOP L8, 2001 requirements.





to be put in hand.

1M 3. Hot water

temperature (at

outlet of calorifier).


ACOP L8, 2000 requirements.





to be put in hand.

1MOther

4. Drain valves. Open to ensure blow down of

collected sediment.To be carried

out in a safe manner. Requires

method statement for minimal

aerosolation.

This is particularly applicable in

vacant buildings where services are

left running and more frequent

opening of drain valves is

recommended.

12M 4. Drain valves. Open to ensure blow down of

collected sediment. To be carried

out in a safe manner. Requires

method statement for minimal

aerosolation.

This is particularly applicable in

vacant buildings where services are

left running and more frequent

opening of drain valves is

recommended.

12MOther

5. Disinfection. If there is a need to disinfect whole

system, advise client.

Refer to ACOP L8 part 2 page 48

paragraph 190

5. Disinfection. If there is a need to disinfect whole

system, advise client.

Refer to ACOP L8 part 2.Other

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CALORIFIER TYPES32-03 32-03 CALORIFIER TYPES

In the context of Building Services the term calorifier is used to describe a closed vessel with a

cylindrical shell fitted with heat transfer surface. The water in the calorifier is heated indirectly by the

tubular primary heater with hot water, steam or electrical immersion heating elements. A calorifier is

used for the supply of a hot water service, for central heating purposes and for industrial applications.

ACOP L8 also defines calorifiers in the glossery.

(a) Non-storage, normally used for heating systems

(b) Storage, normally used for hot water supply systems where demand usually varies.

This section covers the maintenance of calorifiers including calorifier mountings and unvented hot

water systems but is not intended to cover the opening up of calorifiers for statutory insurance

inspection which requires a separate procedure, which may be carried out at the same time as the

maintenance.

In the context of Building Services the term calorifier is used to describe a closed vessel with a

cylindrical shell fitted with heat transfer surface. The water in the calorifier is heated indirectly by the

tubular primary heater with hot water, steam or electrical immersion heating elements. A calorifier is

used for the supply of a hot water service, for central heating purposes and for industrial applications.

ACOP L8 also defines calorifiers in the glossary.

(a) Non-storage, normally used for heating systems or where there is low demand for hot water

(b) Storage, normally used for hot water supply systems where demand usually varies.

This section covers the maintenance of calorifiers including calorifier mountings and unvented hot

water systems but is not intended to cover the opening up of calorifiers for statutory insurance

inspection which requires a separate procedure, which may be carried out at the same time as the

maintenance.Technical

Other

Page 317 of 614

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In accordance with good practice the operator should carry out a visual inspection of the calorifier at

regular intervals and this should include checking for leaks.



(a) Check equipment operating status (i.e. whether in operation or not in use, whether isolated from


(b) Inspect calorifier insulation and/or shell for signs of damage.

(c) Inspect all manholes, mounting, and joints for signs of leaks.

(d) Report any necessary remedial work where repairs, adjustment or replacement will be required


(e) Check condition of sacrificial anode and replace if necessary.

PASTEURISATION

All secondary systems used to provide a hot water service must be chlorinated/pasteurised yearly in

accordance with ACOP L8,2001 and additionally after a period of shutdown.

In accordance with good practice the operator should carry out a visual inspection of the calorifier at





system) including safety. This includes obtaining any necessary Permit to Work`s from the Authorised

Person.


(c) Inspect all manholes, mounting, and joints for signs of leaks.



PASTEURISATION

All secondary systems used to provide a hot water service must be chlorinated/pasteurised yearly in

accordance with ACOP L8,2000 (www.hse.gov.uk) and additionally after a period of shutdown. If a

calorifier or any substantial part of a hot water system is on standby

use or has been taken out of service for longer than 1 week, the water in the calorifier should be

brought up to 60°C for 1 hour before being used; this should be measured with normal circulating

pumps operating and not with the system in a stagnant state.Technical

Other

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CALORIFIERS HEATED BY LTHW OR MTHW32-05 32-05 CALORIFIERS HEATED BY LTHW

Warning – Insulation may contain Asbestos

Low temperature hot water systems (LTHW or LPHW) are heating systems operating up to 10 bar

(gauge) and 95°C, medium temperature hot water systems [MTHW] are heating systems operating in

the range 95°C-120°C and indirect systems complementary to them.





(b) (b) Inspect calorifier insulation and/or shell for signs of damage.

(c) (c) Inspect all manholes, mounting and joints for signs of leaks.



Check condition of sacrificial anode and replace if necessary.

PASTEURISATION

All secondary systems used to provide a hot water service must be pasteurised after a period of

shutdown or standby over a one week period in accordance with ACOP L8 2001 and HTM 04 Part A &

B. This includes shutdown to inspect calorifiers.

Warning – Insulation may contain Asbestos

Low temperature hot water systems (LTHW or LPHW) are heating systems operating up to 95°C,


detailed in 32-04 should be followed:




(c) Inspect all manholes, mounting and joints for signs of leaks.



PASTEURISATION (Domestic Hot Water Calorifiers)


shutdown or standby over a one week period in accordance with ACOP L8 2000 and HTM 04 Part A &


Legislative


1. Operation and

safety controls.


defects.

Ensure both secondary and primary

circuits are full of water and circuits

are open.

12M 1. Operation and

safety controls.


defects. Ensure an

Anti-stratification pump has been

fitted on the secondary side of the

calorifier and it is operational



are open.

12MTechnical

2. Safety

valves/PRV.

Check operation of safety. N.B. Temperature settings should be

in accordance with HSE guidance

note ACOP L8, 2001 for Hot Water

Services. If manually operated for

test purposes leakage could occur

after test.

12M 2. Safety

valves/PRV.

Check operation of safety. If manually operated for test

purposes leakage could occur after

test.

12MTechnical

3. Thermostats,

pressure sensors,

altitude gauges

and thermometers.


settings; set against Certified

masters,

12M 3. Thermostats,

pressure sensors,

altitude gauges

and thermometers.


settings; set against Certified

masters,

N.B. Temperature settings should

be in accordance with HSE

(www.hse.gov.uk) guidance note

ACOP L8, 2000 for Hot Water

Services.

12MTechnical

8. Sacrificial

anode

Check status.24M 8. Sacrificial

anode

Check status. Replace as necessary24MTechnical

9. Put back into

operation

Refit all manholes, refill secondary

side. Hydraulic pressure test. Put

primary side into operation.

Check operation of all temperature

controls. Carry out item 6

9. Put back into

operation

Refit all manholes, refill secondary

side. Hydraulic pressure test. Put

primary side into operation.


controls. Carry out item 3

12MOther

10.

Pasteurisation.

Hold Temperature one hour above

60°C. prior to reinstatement.

Procedure as laid down in HTM 04

Part B Page 23 paragraph 7.74

12M 10.

Pasteurisation.



Procedure as laid down in ACOP

L8: 2000, paragraph 154 and HTM

04 Part B.

12MLegislative

11. Bursting discs Check condition. Report findings.12M Deleted

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HOT WATER CALORIFIERS HEATED BY STEAM32-06 32-06 HOT WATER CALORIFIERS HEATED BY MTHW, HTHW or STEAM

WARNING - If insulation looks damaged - STOP WORK - this may be Asbestos - Appropriate action

must be taken prior to further works. If the insulation is known or CERTIFIED not to be Asbestos,

continue as follows: -

Note: In the interests of safety and the prevention of scalding, water temperatures and the operation

of blending valves should be checked at least once a month by the caretaker or operator.

Warning STEAM LEAKS ARE DANGEROUS





(e) (e) Inspect calorifier insulation and/or shell for signs of damage.

(f) (f) Inspect all manholes, mounting and joints for signs of leaks.

(g) Report any necessary remedial work where repairs, adjustment or replacement will be required


(h) Check condition of sacrificial anode and replace if necessary.

PASTEURISATION


shutdown or standby over a one week period in accordance with ACOP L8,2001 and HTM 04 Part A &


Most MTHW, HTHW and Steam Calorifiers will be under the control of an Authorised Person. A permit

to Work must be issued by the Authorised Person before any work can commence on a Calorifier

WARNING - If insulation looks damaged - STOP WORK- this may be Asbestos - Appropriate

action must be taken prior to further works. If the insulation is known or CERTIFIED not to be

Asbestos, continue as follows: -

In the interests of safety and the prevention of scalding, water temperatures and the operation of

blending valves should be checked at least once a month by the caretaker or operator. See SFG

32-01 for further information on temperatures etc.

Warning WATER AND STEAM LEAKS ARE DANGEROUS



(a) At the entrance to the Plant room, Stop and Listen for a steam leak (High Pressure steam will be




(c)Inspect calorifier insulation and/or shell for signs of damage.

(d)Inspect all manholes, mounting and joints for signs of leaks.

(e) Report any necessary remedial work where repairs, adjustment or replacement will be required


PASTEURISATION (Domestic Hot Water Calorifiers)


shutdown or standby over a one week period in accordance with ACOP L8,2000 (www.hse.gov.uk)

and HTM 04 Part A & B. This includes shutdown to inspect calorifiers.

Legislative


15. Check

insulation for

damage.







12M 16. Check

insulation for

damage.







12MOther

16. Hydraulic

pressure test.


Working pressure x 1.1.

Pressure Regulations 1989 may

apply. (see INDG 261)

12M 17. Hydraulic

pressure test.


110% of working pressure.



12MLegislative

1. Check

operation, in

particular safety

controls.

Note and report any visible defects. Ensure secondary is full of water




12M 1. Check

operation, in

particular safety

controls.


defects. Ensure an



calorifier and it is operational.

Ensure secondary is full of water




12MTechnical

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3. Thermostats,

pressure sensors,

altitude gauges

and thermometers.


settings, set against Certfied

masters.

Temperature settings for Hot Water

Services should be in accordance

with HSE ACOP L8, 2001 and HTM

04 Part B.

12M 3. Thermostats,

pressure sensors,

altitude gauges

and thermometers.



masters.



with HSE ACOP L8, 2000

(www.hse.gov.uk)

12MTechnical

4. Auto controls

and primary side.






cut-outs.

12M 4. Auto controls

and primary side.






cut-outs. This may include obtaining

a Permit to Work from an Authorised

Person.

12MTechnical

5. Drain

valve/drain cock

on secondary side.



N.B. If calorifier was in use, the

secondary water will be hot, and can



schedule.

12M 5. Drain

valve/drain cock

on secondary side.




secondary water will be hot, and can



schedule.

12MTechnical

8. Sacrificial

anode.

Check status12M 8. Sacrificial

anode.

Check status. Replace as necessary.12MTechnical

12. Return to

operation.


refit all manhole covers, refill

secondary side and put primary

side back into operation.


correctly. Carry out item 6

12M 13. Return to

operation.


refit all manhole covers, refill

secondary side and put primary

side back into operation.


correctly. Carry out item 6

12MOther

13.

Pasteurisation.





12M 14.

Pasteurisation.





04 Part B.

12MLegislative

14. Bursting discs

(where fitted).

Check condition. Report findings.24M 15 Bursting discs

(where fitted).

Check condition. Report findings.24MOther

12 Internal

Inspection

Arrange for an internal inspection to

be carried out by a Competent

Person as required by the Written

Scheme of Examination.



12MAdded

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HOT WATER SUPPLY CALORIFIERS - including LOAD LEVELLERS32-07 32-07 HOT WATER SUPPLY CALORIFIERS


detailed in 32-04 should be followed:





Added


7. Sacrificial

anode.

Check status. Replace as necessary.12MAdded

1. Operation and

safety controls.


defects.



are open.

12M 1. Operation and

safety controls.


defects. Ensure an



calorifier, where it is required and it

is operational and does not run

continuously



are open.

12MLegislative

2. Safety valves. Check for corrosion and manually

operate.





schedule.

12M 3. Safety valves. Check for corrosion and manually

operate.





schedule.

12MOther

3. Thermostats,

pressure sensors,

altitude gauges

and thermometers.


settings, set against Certfied

masters.

N.B. Temperature settings for Hot

Water Services should be in

accordance with HSE ACOP

L8,2001. With direct acting valves

hot water storage temperatures

should not exceed those laid down

in the above guidance notes or

scalding could occur.

12M 4. Thermostats,

pressure sensors,

altitude gauges

and thermometers.



masters.



with HSE ACOP L8,2000

(www.hse.gov.uk). With direct

acting valves hot water storage

temperatures should not exceed

those laid down in the above

guidance notes or scalding could

occur.

12MOther

4. Auto controls

and primary side.

Shut down primary heat source. Check operation of temperature

controls and high limit cut-outs.

12M 5. Auto controls

and primary side.

Shut down primary heat source. Check operation of temperature

controls and high limit cut-outs.

12MOther

5. Drain

valve/drain cock

on secondary side.







schedule.

12M 6. Drain

valve/drain cock

on secondary side.







schedule.

12MOther

6. Heating

surface and

internal surfaces

of shell.

Drain down secondary side,

remove manhole covers and

inspect for scale formation and

corrosion and report.



wastage. In hard water areas scale

can be very difficult to remove if left

to build up and more frequent

maintenance is recommended.

Corrosion will cause metal failure

and leakage. Remember Waste

Disposal Regulations.

24M 8. Heating

surface and

internal surfaces

of shell.

Drain down secondary side, remove


scale formation and corrosion and

report.



wastage. In hard water areas scale

can be very difficult to remove if left

to build up and more frequent

maintenance is recommended.

Corrosion will cause metal failure

and leakage.

24MOther

7. Bursting discs

(where fitted).

Check condition. Report findings.24M 9. Bursting discs

(where fitted).

Check condition. Report findings.24MOther

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8. Put back into

operation

Refit all manhole covers, refill

secondary side. Put primary side



controls

10. Put back into

operation

Refit all manhole covers, refill

secondary side. Put primary side



controls.

Other

2 Storage

Temperature

Check and record the calorifier

water storage temperature

It is recommended that the hot

water should be stored at 60oC

(ACOP L8). Where temperatures

are recorded below 60oC, increase

set point to achieve the desired

temperature. If the temperature

cannot be maintained, report to

Client

1WAdded

11. Pasteurisation Hold temperature one hour above



L8: 2000 and HTM 04 Part B

12MAdded

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CALORIFIER AND HEAT EXCHANGE CONTROLS32-08 32-08 CALORIFIER AND HEAT EXCHANGE CONTROLS

Certain common maintenance procedures should be carried out for all controls. These are:

1. All control items, e.g. thermostats and the like, that have switching contacts ensure contacts make

and break easily and that there is no arcing or pitting.




end of the pocket).

5. Inspect motorised valves for leakage and damage to linkage



Certain common maintenance procedures should be carried out for all controls. These are:

1. All control items, e.g. thermostats and the like, that have switching contacts ensure contacts make

and break easily and that there is no arcing or pitting



4. Ensure immersion thermostats are secure in their pockets (and that the sensor is in contact with

the end of the pocket).

5. Inspect motorised valves for leakage and damage to linkage



Other


2. High limit

thermostat (if

fitted).

Check operation and confirm set

point.

Manual or thermal reset?12M 2. High limit

thermostat (if

fitted).


point.

12MOther

3. Temperature

sensor controller.

Motorised valve.


point(s).

12M 3. Temperature

sensor controller.

Motorised valve.


point(s).

For guidance on Motorise valves

see Valves - automatic control SFG

62.

12MTechnical

4. Power fail

return. Motorised

valve.

Check operation. Ensure valve shuts off supply to

calorifier and does not have let-by.

12M 4. Power fail

return. Motorised

valve.

Check operation. Ensure valve shuts off supply to

calorifier and does not have let-by.

See Actuators SFG 01-07 and

01-08.

12MTechnical

5. Direct acting

control valve.


point.

12M 5. Direct acting

control valve.


point.



62.

12MTechnical

6.Direct acting

control valve - high

limit.


point.

12M 6.Direct acting

control valve - high

limit.


point.



62.

12MOther

7. Temperature

sensor.

Controller.

Motorised valve.

Power fail return

motor.

Check performance. Calibration } Interrogation } by

CONTROLS SPECIALIST. Control

adjustment advance

12M 7. Temperature

sensor.

Controller.

Motorised valve.

Power fail return

motor.

Check performance.12MOther

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HOT WATER CYLINDERS32-09 32-09 HOT WATER CYLINDERS

Prior to carrying out the planned maintenance of the cylinder, the pre-maintenance procedure detailed

in 32-04 should be followed:







PASTEURISATION




Added


11. Temperature

sensor

Ensure that the temperature sensor

has a good surface to surface

contact with the cylinder.

12MAdded

1. Cylinder. Inspect visible seams and bosses

for leaks or signs of corrosion.

Report adverse findings.12M 2. Cylinder. Inspect visible seams and bosses


Report adverse findings.12MOther

2. Connections. Check connecting pipe unions for

leaks.

If found, drain down, clean and

remake joint.

12M 3. Connections. Check connecting pipe unions for

leaks.


remake joint.

12MOther

3. Insulation. Inspect for deterioration. Refer to client if repairs or renewal

required.

12M 4. Insulation. Inspect for deterioration. Refer to client if repairs or renewal

required.

12MOther

4. Immersion

heater.

Check operation and examine for

scale on element.

Client's attention should be drawn to

the presence of excessive scale,

which indicates the need for water

treatment.

12M 5. Immersion

heater.


scale on element.

client`s attention should be drawn to

the presence of excessive scale,


treatment.

12MOther

5. Cold water

storage cistern (if

combination

cylinder).

Inspect seams and bosses for

leaks.

Report adverse findings.12M 6. Cold water

storage cistern (if

combination

cylinder).


leaks.


6. Float operated

valve and float (if

combination

cylinder).

Check operation and adjust water

level to maximum storage level.

Check float for leakage and

security.

Re-washer or replace if necessary.

Replace if necessary.

12M 7. Float operated

valve and float (if

combination

cylinder).


level to maximum storage level.

Check float for leakage and

security.



12MOther

7. Water

temperature.

Check water outlet temperature

and operation of auto-temperature

controls.

N.B. Temperature setting for Hot


accordance with HSE ACOP L8,

2001.

12M 9. Water

temperature.

Check water outlet temperature and

operation of auto-temperature

controls.

Temperature setting for Hot Water



(www.hse.gov.uk) and HTM 04-01

Part A.

12MOther

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1 Storage

Temperature










Client

1WAdded

8. Pasteurisation Hold Temperature one hour above



L8: 2000 and HTM 04 Part B

12MAdded

8. Integral Cold

Water Storage (if

combination

cylinder)

Inspect cold water storage, clean

as necessary.

See STORAGE - COLD WATER for

detailed maintenance schedule of

cisterns. Where these units are

used infrequently or low usage the

cold water storage is likely to rise

above 20ºC therefore promoting the

liklyhood of Legionella poliferaton.

For this reason integral cisterns

should be kept clean and conform to

the Water Supply (Water Fittings)

Regulations 1999.HTM 04 for health

care recommends that these units

are not used.

6M 10. Integral Cold

Water Storage (if

combination

cylinder)

Inspect cold water storage, clean as

necessary.

See STORAGE TANKS - COLD

WATER STORAGE TANKS AND

CISTERNS (SFG 56-02) for detailed

maintenance schedule of cisterns.

Where these units are used

infrequently or low usage the cold

water storage is likely to rise above

20oC therefore promoting the

likelihood of Legionella proliferation.




Regulations 1999. HTM 04 for

health care recommends that these

units are not used.

6MOther

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UNVENTED HOT WATER SYSTEMS32-10 32-10 UNVENTED HOT WATER SYSTEMS


2. Discharge

pipework.

Examine discharge pipes, ensure

that air gap is clear and that there

is no blockage in the pipes.

Discharge pipe should be visible

and in a safe place. It should be of

metal and connected to the tundish.

12M 2. Discharge

pipework.


that air gap is clear and that there is

no blockage in the pipes.



metal and connected to the tun dish.

12MOther

3. Expansion

relief valve.

Manually operate. Check that the valve seats

satisfactorily, water flow ceased on

valve closure and water runs

through tundish and discharge

pipes.

3M 3. Expansion

relief valve.

Manually operate. Check that the valve seats

satisfactorily, water flow ceased on

valve closure and water runs

through tun dish and discharge

pipes.

3MOther

5. High limit

thermostat.

Check operation. Should be non self-setting. Thermal

cut out should be 85b0C.

6M 5. High limit

thermostat.


cut out should be 85°C.

6MOther

6. Control

thermostat.

Check temperature setting. N.B. Temperature settings for Hot



2001.

12M 6. Control

thermostat.

Check temperature setting. Temperature settings for Hot Water




Part A.

12MTechnical

7. Diaphragm

expansion tank.

Check pressure. See EXPANSION VESSELS .12M 7. Diaphragm

expansion tank.

Check pressure. See Hot water supply - expansion

vessels SFG 32-12.

12MOther

8. Motorised

valve (if fitted).

Check operation. Ensure no water flows through

valves during shut down part of the

cycle.

12M 8. Motorised

valve (if fitted).



cycle. For further guidance see

Valves - automatic control SFG 62.

12MTechnical

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THERMAL STORAGE CYLINDER (individual dwellings for DHWS)32-11 32-11 THERMAL STORAGE CYLINDER (individual dwellings for DHWS)

PASTEURISATION




Added


10. Temperature

sensor

Ensure that the temperature sensor

has a good surface to surface

contact with the cylinder.

12MAdded

1. Cylinder. Inspect visible seams and bosses


Report adverse findings.12M 2. Cylinder. All secondary systems used to

provide a hot water service must be

pasteurised after a period of

shutdown or standby over a one

week period in accordance with

ACOP L8,2000 (www.hse.gov.uk)

and HTM 04 Part A & B. This

includes shutdown to inspect

calorifiers.


2. Connections. Check connecting pipe unions for

leaks.


remake joint.

12M 3. Connections. Check connecting pipe unions for

leaks.


remake joint.

12MOther

3. Insulation. Inspect for deterioration. Refer to client if repairs or renewal

required.

12M 4. Insulation. Inspect for deterioration. Refer to client if repairs or renewal

required.

12MOther

4. Immersion

heater.


scale on element.

Clients attention should be drawn to

the presence of excessive scale


treatment.

12M 5. Immersion

heater.


scale on element.

clients attention should be drawn to

the presence of excessive scale


treatment.

12MOther

5. Feed and

expansion cistern

(if fitted).


leaks.

Report adverse findings.12M 6. Feed and

expansion cistern

(if fitted).


leaks.

Report adverse findings. Ensure

tanks meet the requirements of

ACOP L8:2000 regarding

cleanliness, lids, screens etc.

12MTechnical

6. Float operated

valve and float (if

fitted).


level to minimum make up level.

Check float for leakage.


Water level adjustments should only

be carried out when the heating

system and cylinder are cold.



valve and float (if

fitted).


level to minimum make up level.

Check float for leakage.


Water level adjustments should only

be carried out when the heating

system and cylinder are cold.


12MOther

7. Domestic hot

water thermostatic

blender.

Check operation. Check water

outlet temperature and operation of

auto-temperature controls.




2001.

12M 9. Domestic hot

water thermostatic

blender.

Check operation. Check water

outlet temperature and operation of

auto-temperature controls.




2001 (www.hse.gov.uk) and HTM

04-01 Part A.

12MTechnical

1 Storage

Temperature










Client

1WAdded

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8. Pasteurisation Hold Temperature one hour above




04 Part B.

12MAdded

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EXPANSION VESSELS32-12 32-12 EXPANSION VESSELS


3. Drain Discharge by flushing. In most installations the vessel will

be a source of contamination by

acting as a deadleg.

1W 3. Drain Discharge by flushing. In most installations the vessel will

be a source of contamination by

acting as a dead leg.

1WOther

1. Diaphragm

expansion tank/s.

Check. Ensure air cushion pressure is

correct, if necessary top up,

preferably with oxygen free nitrogen.

Remove diaphragm from shell,

check and report on condition of

both. Ensure cushion pressure is

correct when re-commissioned.

3M 1. Diaphragm

expansion tank/s.

Check. Ensure gas cushion pressure is

correct, if necessary top up,

preferably with oxygen free nitrogen.

Remove diaphragm from shell,

check and report on condition of

both. Ensure cushion pressure is

correct when re-commissioned.

A risk Assesment must be done

prior to its use, suitable training

must also be given prior.

3MTechnical

Page 330 of 614

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DIRECT FIRED WATER HEATERS32-13 32-13 DIRECT FIRED WATER HEATERS

Heater generation may be by electricity, light oil pressure jet burners, forced draught but usually

atmospheric gas burners. For specific maintenance instructions on heat generator see appropriate

Burner Section.

WARNING: To avoid the possible risk of scalding, Thermostatic Mixing Valves (TMV’s) must be

considered in line with a risk assessment where vulnerable persons are likely to use the outlets. All

other outlets not blended should have hot water warning signs. Client should carry out monthly checks

of the outlet temperature where blended.

Heater generation may be by electricity, light oil pressure jet burners, forced draught but usually

atmospheric gas burners. For specific maintenance instructions on heat generator see appropriate

Boilers - heat generators SFG 05.

Special note:

Certain heaters called `Energy saver water heaters` will have an electrically operated damper in the

flue to reduce ventilation losses through the heater. The operation sequence is when the thermostat

calls for more heat the damper opens, changing the contacts on a microswitch. This then provides

power to the heat generation equipment.

WARNING: To avoid the possible risk of scalding, Thermostatic Mixing Valves (TMV’s) must

be considered in line with a risk assessment where vulnerable persons are likely to use the outlets. All

other outlets not blended should have hot water warning signs. client should carry out monthly checks

of the outlet temperature where blended.

Department of Health, HTM 04-01 Part A sets out the safe water temperatures and appropriate

delivery devices (TMV`s) over a range of areas/activities.

Technical


1. Heat

generation

equipment.

Remove and carry out necessary

maintenance.

See HEAT GENERATORS for

maintenance.

12M 1. Heat

generation

equipment.

Remove and carry out necessary

maintenance.

See Boilers - heat generators SFG

05 for maintenance.

12MTechnical

7. Smoke test. Carry out and smoke test on flue. See under FLUES.12M 7. Smoke test. Carry out and smoke test on flue. See under Flues SFG 24-01.12MTechnical

1. Isolation. Turn off, isolate and remove heat

generator. Where applicable,

switch off electricity and remove

fuses. Turn off water supply.

See BURNER section maintenance.12M 1. Isolation. Turn off, isolate and remove heat

generator. Where applicable,

switch off electricity and remove

fuses. Turn off water supply.

12MTechnical

8. Pasteurisation. Hold Temperature one hour above




12M 8. Pasteurisation. Hold Temperature one hour above




04 Part B.

12MTechnical

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INSTANTANEOUS ELECTRIC WATER HEATERS32-14 32-14 INSTANTANEOUS ELECTRIC WATER HEATERS (non drinks type)


2. Water

temperature.

Check water outlet temperature

and operation of auto-temperature

controls.

N.B. Temperature settings should be

in accordance with ACOP L8, 2001

for Hot Water Services, i.e. 60°C.

Beware of scalding, consider TMV’s.

12M 2. Water

temperature.

Check water outlet temperature and

operation of auto-temperature

controls.



(www.hse.gov.uk) for Hot Water

Services, i.e. 60°C.

12MOther

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PACKAGED ELECTRIC WATER HEATERS-cistern type32-15 32-15 PACKAGED ELECTRIC WATER HEATERS-cistern type (non drinks)


1. General. N.B. The exact maintenance

procedure will depend upon the

make and configuration as most

packaged units have different

design arrangements.

1. General. The exact maintenance procedure

will depend upon the make and

configuration as most packaged

units have different design

arrangements.

Other

2. Operating

status.

Check, if unit out of service ask

client for reasons.

If electrically defective, ensure

equipment is left disconnected and

isolated. Ensure supply is cut off at

spur to avoid deadlegs.

12M 2. Operating

status.

Check, if unit out of service ask

client for reasons.

If electrically defective, ensure

equipment is left disconnected and

isolated. Ensure water supply is

isolated at spur to avoid deadlegs.

12MTechnical

4. Water

temperature

controls.

Measure temperature, check

against thermostat settings. Adjust

thermostat as necessary.



for Hot Water Services i.e. 60°C.

Beware of scalding, consider TMV’s

12M 4. Water

temperature

controls.

Measure temperature, check

against thermostat settings. Adjust

thermostat as necessary.

Temperature settings should be in

accordance with ACOP L8, 2000

(www.hse.gov.uk) for Hot Water

Services i.e. 60°C.

12MOther

8. Integral cold

storage

Inspect cold water storage, clean

as necessary.




20°C therefore promoting the

liklyhood of Legionella poliferaton.




Regulations 1999.

6M 8. Integral cold

storage

Inspect cold water storage, clean as

necessary.




20°C therefore promoting the

likelihood of Legionella proliferation.




Regulations 1999.

6MOther

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32-16 VENTED HOT WATER SYSTEMS

It is recommended that the hot water should be stored at 60oC (ACOP L8). Where temperatures are

recorded below 60oC, increase set point to achieve the desired temperature. If the temperature

cannot be maintained, report to Client

Added


1. Temperature

relief valve.

Manually operate.3MAdded

2. High limit

thermostat.


cut out should be 85°C.

6MAdded

3. Complete unit. Examine water storage vessel,

pipework and fittings.

Check for any signs of corrosion

and water leaks. Reseal pipework

joints if necessary.

12MAdded

4. Discharge

pipework.


that air gap is clear and that there is

no blockage in the pipes.



metal and connected to the tun dish.

12MAdded

5. Control

thermostat.

Check temperature setting. Temperature settings for Hot Water




Part A.

12MAdded

6. Motorised

valve (if fitted).



cycle. For further guidance see

Valves - automatic control SFG 62.

12MAdded

7. In-line strainer. Inspect and clean as required.12MAdded

8. Back flow

prevention device.

Check operation and ensure that

non-return valve is seating properly.

The operation can be checked by

observing any changes in the

upstream level of a vessel

preceding the device when the

incoming supply is isolated.

12MAdded

9. Electrical

element.

Check for scale on element. Client`s attention should be drawn

to presence of excessive scale

which indicates a possible need for

water treatment or water

conditioning.

12MAdded

Page 334 of 614

HUMIDIFIERS INCLUDING DISINFECTION PROCEDURES

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HUMIDIFIER - Cold water evaporator, drum type33-01 33-01 HUMIDIFIER - Cold water evaporator, drum type

Any action taken must conform to HSE requirements, The control of Legionella bacteria in water

systems – ACOP L8,2001 and HEVAC code of best practice - 1.

Note: In hard water areas more frequent maintenance may be required.

Any action taken must conform to HSE requirements, the control of Legionella bacteria in water

systems – ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice 4

commissioning and planned maintenance.

Persons responsible for maintenance should record who the competent persons responsible for

maintenance are, tests and results, routine maintenance, cleaning and disinfection dates, as per the

HSE’s Code of Practice L8.

In hard water areas more frequent maintenance may be required.

All monitoring and maintenance activity should be recorded in a log, particularly that relating to

Legionella monitoring and control.

Technical


1. Status. Isolate electrically and hydraulically. Note: electrical isolation should

meet HSAWA requirements.

3M 1. Status. Isolate electrically and hydraulically. Electrical isolation should meet

HSAWA (www.hse.gov.uk)

requirements.

3MOther

2. Rotor filter

pads.

Closely inspect. Replace filter pads

as necessary. On reassembly use

new gaskets where necessary.

Report condition. If filter pads need

replacement it is necessary to first

clean the rotor.

12M 2. Rotor filter

pads.

Closely inspect. Replace filter pads

as necessary. On reassembly use

new gaskets where necessary.

Report condition. If filter pads need

replacement it is necessary to first

clean the rotor.

3MTechnical

9. Motor gear

box.

Change oil. See also MOTORS12M 9. Motor gear

box.

Change oil. See also Motors SFG 29-0112MOther

11. Return to

service.

Check operation. Ensure compliance with HSC ACOP

L8, 2001.

12M 11. Return to

service.

Check operation. Ensure compliance with HSC

ACOP L8, 2000 (www.hse.gov.uk).

12MOther

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HUMIDIFIER - Direct steam injection type.33-02 33-02 HUMIDIFIER - Direct steam injection type.

Note:- When in operation, there is intermittent live steam injected from manifold within. DO NOT

ATTEMPT TO SERVICE WITHOUT ISOLATING STEAM AND ELECTRICITY SUPPLIES FIRST.

Any action taken must conform to HSE requirements, The control of Legionella bacteria in water






Note:- When in operation, there is intermittent live steam injected from manifold within. DO NOT

ATTEMPT TO SERVICE WITHOUT ISOLATING STEAM AND ELECTRICITY SUPPLIES FIRST.

If the system has been out of operation for more than 3 months then the system should undertake a

yearly maintenance and then be subject to a re-commission.



Technical


2. System Check any flange bolts for tightness

and adjust as required. Check all

gland seals adjust as required.

Visually inspect all pipe work and

joints for leaks.

1MAdded

15. Valves Inspect all valves for wear or scale

deposits. Worn or damaged parts

should be replaced as well as the

gland seal packaging. Check for

complete isolation and free

movement.

Graphite packaging is subject to

wear. It is therefore recommended

to replace such items.

12MAdded

18. Switch off

devices

Check the function of the switch-off

devices, e.g. the max hygrostat.

12MAdded

1. Status. Isolate electrically. Note: electrical isolation should


3M 1. Status. Isolate electrically. Electrical isolation should meet


requirements.

3MOther

2.Removal of

deposits.

Clean and flush out. Note: If automatic time controlled

flush out valve is fitted, check

correct operation by overriding

timer. It may be necessary from time

to time to adjust between automatic

flushing depending upon

humidification requirements which

can vary with the weather

conditions.

3M 3.Removal of

deposits.

Clean and flush out the steam

cylinder.

If automatic time controlled flush out

valve is fitted, check correct

operation by overriding timer. It

may be necessary from time to time

to adjust between automatic flushing

depending upon humidification

requirements which can vary with

the weather conditions.

3MOther

3. Ball valve. Check operation. Clean and renew

washer.

3M 4. Ball valve. Check operation. Clean and renew

washer.

See Valves SFG 613MTechnical

4. Water level. Check level in gauge glass

corresponds with indicator plate.

3M 5. Water level. Check level in gauge glass

corresponds with indicator plate.

3MOther

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5. Humidistat. Check operation, clean if

necessary.

Use a sling hydrometer to check

accuracy of operation.

3M 6. Humidistat. Check operation, clean if

necessary. For Further Guidance

see Sensors and Switching Devices

SFG 50-04 and 50-05

Use a hand held hydrometer to

check accuracy of operation.

3MOther

6. Misting sprays. Observe spray pattern, clean if

necessary.

Clean with compressed air. Do not

use wire or pointed objects as these

will enlarge the orifices and lead to a

poor misting pattern.

3M 7. Misting sprays. Observe spray pattern, clean if

necessary.

Clean with compressed air. Do not

use wire or pointed objects as these

will enlarge the orifices and lead to a

poor misting pattern.

3MOther

7. Control and

indicator lights.

Check for correct functioning.3M 8. Control and

indicator lights.

Check for correct functioning.3MOther

8. Steam traps. Check operation condition of filters

and sight glasses.

Ensure condensate drain is clear.3M 9. Steam traps. Check operation condition of filters

and sight glasses.

Ensure condensate drain is clear.3MOther

8. Steam traps. Check operation condition of filters

and sight glasses.

3M Deleted

9. Steam

pressure.

Check.3M 10. Steam

pressure.

Check.3MOther

10. Strainer

(where fitted).

Check strainer on steam supply.3M 11. Strainer

(where fitted).

Check strainer on steam supply

clean or replace as necessary.

3MTechnical

11.Water supply. Turn off at ball valve and empty via

drain cock.

12M 12.Water supply. Turn off at ball valve and empty via

drain cock. Disconnect the water

supply and remove the fill valve

from the humidifier. Remove the

inlet strainer. Clean the fill valve

and inlet strainer using the same

solution as used to clean the steam

cylinder.

12MTechnical

12. Steam

chamber.

Remove out casing lid baffles.

Remove any scale either physically

or by using suitable chemical

descaling agent.

Ensure that any sludge or scale

deposits are removed from the

bottom of the steaming chamber.

Additional access may be provided

on the side of the vessel to facilitate

cleaning. Waste Disposal


12M 13. Steam

chamber.

Remove out casing lid baffles.

Remove any scale either physically

or by using suitable chemical

descaling agent. If the electrodes

are deteriorated, replace the steam

cylinder rather than

cleaning it.

Ensure that any sludge or scale

deposits are removed from the

bottom of the steaming chamber.

Additional access may be provided

on the side of the vessel to facilitate

cleaning. Waste Disposal


12MTechnical

13. Feed water

line.

Check that it is clear.12M 14. Feed water

line.

Check that it is clear.12MOther

14. Re-assembly. Ensure all joint faces are clean and

re-assemble using new gaskets.

12M 16. Re-assembly. Ensure all joint faces are clean and

re-assemble using new gaskets. If

the unit does not restart and go to

normal operation, then the

electrodes may be too badly

deteriorated to be reused and the

cylinder must be replaced.

12MTechnical

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15.

Re-commission.

Put back into service and check

water level in gauge glass

corresponds with indicator plate,

ball valve operates correctly,

controls and indicator lights

function properly.

12M 17.

Re-commission.

Put back into service and check

water level in gauge glass

corresponds with indicator plate,

ball valve operates correctly,

controls and indicator lights function

properly.

12MTechnical

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ELECTRODE BOILER HUMIDIFIER33-03 33-03 ELECTRODE BOILER HUMIDIFIER

Note: In hard water areas maintenance may require to be carried out more frequently. If output is

decreased due to heavy scaling renewal of the cylinder will be required, refer to client.

BEWARE High water conductivity in the boiler circulated water can damage the boiler cylinder vessel,

only work within the boiler manufacturers values of conductivity.

Any action taken should conform to the HSE requirements, The control of Legionella bacteria in

water systems – ACOP L8,2001 and HEVAC code of best practice - 1

In hard water areas maintenance may require to be carried out more frequently. If output is decreased

due to heavy scaling renewal of the cylinder will be required, refer to client.




High water conductivity in the boiler circulated water can damage the boiler cylinder vessel, only work

within the boiler manufacturers values of conductivity.

Any action taken should conform to the HSE requirements, The control of Legionella bacteria in water





Technical


1. Status. Check and isolate both water and


Note:- electrical isolation should

meet HSAWA safety requirements.

3M 1. Status. Check and isolate both water and


Electrical isolation should meet

HSAWA (www.hse.gov.uk) safety

requirements.

3MTechnical

2. Steam

cylinder.

Check all electrical connections on

the cylinder for soundness and

correct any defects.

3M 2. Steam

cylinder.

Check all electrical connections on

the cylinder for soundness and

correct any defects. If the

electrodes are deteriorated, replace

the steam cylinder.

3MTechnical

3. Cylinder

exchange.

As per manufacturer's instructions. Cylinder exchange times will vary -

hard water areas 3 months. Soft

water areas 12 months.

3M 3. Cylinder

exchange.

As per manufacturer`s instructions. Cylinder exchange times will vary -

hard water areas 3 months. Soft

water areas 12 months.

The procedure for changing a

cylinder can be found in the

manufacturer’s manual, but also if

the cylinder is to be re-used check

that the electrodes have not rotated

within the cylinder and check that

the seal or “O” ring is still in place.

3MTechnical

6. Feed valve. Clean strainer. Always replace the strainer after

cleaning to prevent material lodging

in the valve.

12M 6. Feed valve. Clean strainer. Disconnect the

water supply and remove the fill

valve from the humidifier. Remove

the inlet strainer. Clean the fill valve

and inlet strainer using the same

solution as used to clean the steam

cylinder

Always replace the strainer after

cleaning to prevent material lodging

in the valve.

12MTechnical

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HUMIDIFIERS- Compressed air type33-04 33-04 HUMIDIFIERS- Compressed air type

Note - this schedule should be read in conjunction with those on air compressors and pressure


Any action taken should conform to the HSE, The control of Legionella bacteria in water systems –

ACOP L8,2001 and HEVAC code of best practice - 1

This schedule should be read in conjunction with those on air compressors and pressure Regulations

may apply.

Any action taken should conform to the HSE, The control of Legionella bacteria in water systems –

ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice 4 commissioning and

planned maintenance.

Systems that generate an aerosol must be tested for Legionella every six months. In certain

applications, such as food retailers, it is recommended the same water is also tested for E.Coli and

coliform bacteria.

Where systems do not incorporate some of the design features outlined above, or where ambient

temperatures exceed 20°C, or where the risk of aerosol inhalation or infection is greater, more regular

sampling will be required. These might be using Dipslides for TVC, or more frequent testing for

Legionella.


maintenance are, water sampling frequency, tests and results, routine maintenance, cleaning and

disinfection dates and details, as per the HSC’s Code of Practice L8.



Legislative


1. Airline

components

Check (visually)inlet and outlet

compressed air and water supply

pressures, visual inspection of the

compressed air filter to check on air

quality, and visual inspection of the

sprays.

1MAdded

6. Water line

components

Water line components in the

control panel are subject to greater

wear and tear particularly in hard

water areas, and sediment filter

elements prior to the control panel

should be changed.

6MAdded

6. Airline

components

Airline components in the control

panel, such as pressure regulators,

pressure switches and solenoid

valves, will require annual

inspection and cleaning. According

to compressed air quality, air filters

immediately prior to the control

panel will need cleaning or

replacement between six months

and a year.

12MAdded

7. UV lamps (if

fitted)

Change UV lamps Weekly inspection of UV-lamp

operation is recommended,

although many compressed air

systems using this technology

incorporate failsafe systems to shut

down the humidifier in the event of

reduced effectiveness or failure.

12MAdded

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1. Status. Isolate electrically and hydraulically. Note: electrical isolation should


3M 2. Status. inspection of the compressed air

filter to check on air quality, and

visual inspection of the sprays.

Electrical isolation should meet


requirements.

3MOther

2. Nozzles. Clean dust and debris from outside

of nozzles.

It is advisable to remove the air caps

annually to clean thoroughly. Take

care not to damage the protective

PTFE coating.

3M 3. Nozzles. Clean dust and debris from outside

of nozzles.

It is advisable to remove the air

caps annually to clean thoroughly.

Take care not to damage the

protective PTFE coating.

3MOther

3. 'Y' strainer. Inspect and replace strainer

screen.

3M 4. `Y` strainer. Inspect and replace strainer screen.3MOther

4. Water

pressure regulator.

Check condition and carry out

maintenance in accordance with

the manufacturer's instructions.

Items which may need periodic

maintenance include:- 2-way air

solenoid valve, 3-way water

solenoid valve, air pressure

regulator.

12M 5. Water

pressure regulator.

Check condition and carry out

maintenance in accordance with

the manufacturer`s instructions.

Items which may need periodic

maintenance include:- 2-way air

solenoid valve, 3-way water

solenoid valve, air pressure

regulator.

12MOther

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HUMIDIFIERS- Ultra sonic33-05 33-05 HUMIDIFIERS- Ultra sonic

Any action taken must conform to the HSE requiements, The control of Legionella bacteria in water

systems – ACOP L8,2001 and HEVAC code of best practice - 1

Any action taken must conform to the HSE requirements, The control of Legionella bacteria in water





coliform bacteria.

Where systems do not incorporate some of the design features outlined above, or where ambient

temperatures exceed 20°C, or where the risk of aerosol inhalation or infection is greater, more regular

sampling will be required. These might be using Dipslides for TVC, or more frequent testing for

Legionella.






Legislative


1. Status. Isolate electrically and hydraulically. Note:- electrical isolation must meet

HSAWA requirements.

6M 1. Status. Isolate electrically and hydraulically. Electrical isolation must meet


requirements.

3MTechnical

2. Water tank. Clean out and refill.6M 2. Water tank. Clean out and refill. Unlike the humidifiers that boil

water, water droplets can contain

any impurities that are in the

reservoir, including minerals from

hard water (which then forms a

difficult to remove white dust on

nearby objects and furniture), and

pathogens growing in a stagnant

water tank.

1MTechnical

3.Ultra sonic

diaphragms.

Clean carefully with soft

non-scratch cloth.

6M 3.Ultra sonic

diaphragms.

Clean carefully with soft

non-scratch cloth.

3MTechnical

5. SEDIMENT

REMOVAL.

Remove as necessary from top of

reservoir.

Operators must wear correctly

graded masks. WASTE DISPOSAL

REGULATIONS APPLY.

1M 5. Sediment

removal.

Remove as necessary from top of

reservoir.

Waste disposal regulations apply.1MOther

6. UVC lamps Change lamps UVC lamps in general have a life of

approximately 8,000 hours, however

due to the nature of their

construction; the

degradation in output accelerates

towards the end of its useful life.

12MAdded

7. Automatic

shutdown and

alarm system

Check that the alarm system (both

audible and visual)works when the

automatic shutdown system

operates. Check that the equipment

shuts down correctly and drains the

water reservoir.

12MAdded

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HUMIDIFIERS- Resistance heater type33-06 33-06 HUMIDIFIERS- Resistance heater type

In hard water areas more frequent maintenance may be required

Any action taken should conform to the HSE requirements, The control of Legionella bacteria in

water systems – ACOP L8,2001 and HEVAC code of best practice - 1

In hard water areas more frequent maintenance may be required









Technical


1. Status. Isolate electrically and hydraulically. Note:- electrical isolation must meet

HSAWA requirements.

12M 1. Status. Isolate electrically and hydraulically. Electrical isolation must meet


requirements.

12MOther

2. Water boiling

chamber.

Drain.12M 2. Water boiling

chamber.

Drain. Check all electrical

connections on the cylinder for

soundness and correct any defects

12MTechnical

4. Scale

collecting bag

(where fitted).

Change as necessary.12M 4. Scale

collecting bag

(where fitted).

Change as necessary. Waste disposal regulations apply.12MTechnical

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HUMIDIFIER - Disinfection procedures33-07 33-07 HUMIDIFIER - Disinfection procedures

All actions should conform with HSE requirements, L8 ACOP and HEVAC code of best practice - 1 All actions should conform with HSE requirements, L8 ACOP and HEVAC Association code of best

practice 4 commissioning and planned maintenance.

Before chemical disinfection is carried out it is essential that the system is clean and it is important to

ensure that all parts of the system are disinfected, not just those which are readily accessible.

Building occupants should be warned that the water is heavily chlorinated. If tanks and calorifiers are

heavily contaminated by organic materials, the system should be disinfected before cleaning to

reduce risks to cleaning staff and also after cleaning. It may be necessary to add chemical dispersants

to remove organic fouling from pipework etc. and chemical descaling may also be necessary. Where

possible, cleaning methods should not create an aerosol.






Technical


1. System. Isolate electrically and hydraulically,

if not already isolated.

Isolation of electrical supply should

be in accordance with HSAWA

requirements.

6M 1. System. Isolate electrically and hydraulically,





6MOther

2.Loose debris. Allow humidity water to drain,

remove solid debris with 'wet and

dry' vacuum cleaner.

6M 2.Loose debris. Allow humidity water to drain,

remove solid debris with `wet and

dry` vacuum cleaner.

Waste disposal regulations apply.6MTechnical

4. Disinfection. Refill system with clean fresh water,

disinfect system with addition of

sodium hypochlorite solution to

achieve free residual chlorine

reserve of 50 mg/l, maintain

circulation for one hour ensuring

the level does not drop below 30

mg/l after one hour.

Ensure drain valve closed during

refill. Note:- Free chlorine is rapidly

absorbed by organic matter and

partially lost when the chlorinated

water cascades through the infill

matter, thus further additions of

sodium hypochlorite may be

required to maintain the free

chlorine reserve at 50mg/litre.

6M 4. Disinfection. Refill system with clean fresh water,

disinfect system with addition of

sodium hypochlorite solution to

achieve free residual chlorine

reserve of 50 mg/l, maintain

circulation for one hour ensuring

the level does not drop below 30

mg/l after one hour.

Ensure drain valve closed during

refill. Free chlorine is rapidly

absorbed by organic matter and

partially lost when the chlorinated

water cascades through the infill

matter, thus further additions of

sodium hypochlorite may be

required to maintain the free

chlorine reserve at 50mg/litre.

6MOther

5. Return to

service.

Drain and thoroughly flush the

sump and operate the pumps for a

further 15 minutes. Drain sump,

test to ensure that residual chlorine

has dropped to below 0.5 mg/l.

Refill sump if unit to be put back

into service immediately.

Particular attention is required if

water used for disinfection is of a

high pH (over 7.3pH) as this will

reduce the effective chlorine. If

using other chemicals for

disinfection, ensure they are WRAS

approved and suppliers method is

followed. All disinfections must be

supported by a detailed disinfection

certificate. NB Chlorine is corrosive

at high levels and other less

aggressive chemicals that are not

pH dependant should be

considered.

6M 5. Return to

service.

Drain and thoroughly flush the

sump and operate the pumps for a

further 15 minutes. Drain sump, test

to ensure that residual chlorine has

dropped to below 0.5 mg/l. Refill

sump if unit to be put back into

service immediately.

Particular attention is required if

water used for disinfection is of a

high pH (over 7.3pH) as this will

reduce the effective chlorine. If

using other chemicals for

disinfection, ensure they are WRAS

approved and suppliers method is

followed. All disinfections must be

supported by a detailed disinfection

certificate. Chlorine is corrosive at

high levels and other less

aggressive chemicals that are not

pH dependant should be

considered.

6MOther

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33-08 SPRAY HUMIDIFIERS



coliform bacteria.

Where ambient temperatures exceed 20°C, or where the risk of aerosol inhalation or infection is

greater, more regular sampling will be required. These might be using dipslides for TVC, or more

frequent testing for Legionella.




In hard water areas maintenance may require to be carried out more frequently. If output is decreased

due to heavy scaling renewal of the cylinder will be required, refer to client.


systems – ACOP L8,2000 (www.hse.gov.uk) and HEVAC Association code of best practice for




Frequency will change depending on the level of contamination and should be subject to local risk

assessment.

Added


1. Non-Chemical

water treatment

Confirm the operation of

non-chemical water

treatment (if present).

1WAdded

1. Status Isolate electrically and hydraulically,





6MAdded

2. Humidifier Clean and disinfect spray

humidifiers/air

washers and make-up tanks

including all

wetted surfaces, descaling as

necessary.

Humidifiers and air washers -

atomising humidifiers and

spray-type air washers may use

water from reservoirs or tanks where

the water temperature exceeds

20°C. Unless they are regularly

cleaned and maintained, they can

become heavily contaminated,

especially in industrial

environments. The risk can be

prevented by using humidifiers

which do not create a spray, i.e.

steam humidifiers. ‘Portable’ or

‘room’ humidifiers of the type that

have a water

supply that is sprayed or atomised

into the room are not

recommended for use in NHS

premises.

6MAdded

Page 346 of 614

ICE MAKING MACHINES

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ICE MAKING MACHINES34-01 34-01 ICE MAKING MACHINES

Cleaning and maintenance of ice machines and storage units is essential in preventing contamination

of ice or equipment. Where possible always follow manufacturer’s instructions for maintenance and

cleaning. A regular cleaning schedule should be established and cleaning and maintenance records

maintained. The client should inspect the interior of the machine twice a week for build up of mould or

other contaminants, and clean accordingly.

The water supply to this equipment should be taken from a potable supply via a double check valve to

prevent backflow. Check that the water supply is taken upstream of a regularly used outlet with the

minimum of intervening pipe-run, that is, less than 3 m. The supply should not be softened.

Additionally, it should be established that the usage is sufficient to avoid deterioration in water quality ,

for example that the inlet water temperature does not exceed 20°C.

The Automatic Vending Association of Britain (AVAB) codes of practice should be followed regarding

hygiene and water quality and hygienic operation of vending machines.

Disconnect ice machines before planned water disruptions.

Added


1. Condition. Empty, check for damage and

clean and disinfect.


required.

12M 1. Condition. Disconnect the unit from the power

supply. Remove and discard ice

from the bin or storage unit and

allow to warm to room temperature.

Inspect for rodent or insect

infestations behind and under the

unit and treat as required. Clean

the ice storage bin with fresh water

and detergent or as recommended

by the manufacturer. Rinse with

clean fresh water. Allow all surfaces

to dry before returning to service.

Some ice storage units require

appropriate sanitation and should

be done so in accordance with



required.

12MOther

2. Door seals (if

fitted).

Check condition, refurbish or


Poorly fitting door seals can lead to

either ice melting or fusion of ice

pieces and energy wastage.

12M 2. Door seals (if

fitted).

Check door gaskets and seals for

evidence of leakage or dripping into

the storage bin. Refurbish or


Poorly fitting door seals can lead to

either ice melting or fusion of ice

pieces and energy wastage.

12MTechnical

5. Controls. Check action. For details see relevant section

CONTROLS.

12M 5. Controls. Check action. For details see relevant section

Control panels and controllers SFG

14.

12MTechnical

6. Drains. Check for blockage, clear if

necessary and disinfect.

12M 6. Drains. Check for blockage, clear if

necessary and disinfect.

Ensure there are proper air gaps

where the condensate lines meet

the waste lines.

12MTechnical

7. Refrigeration

unit.

Check operation. For more detailed maintenance

procedures, see CHILLERS.

12M 7. Refrigeration

unit.


procedures, see Chillers SFG 09.

12MTechnical

9. Ice Scoop Ensure the ice scoop and scoop

receptacle are also cleaned with

neutral detergent and water and

dried on a regular basis or as

specified by the manufacturer

Scoop should be kept on a chain

short enough not to reach the floor.

The scoop should be kept on a

clean hard surface or dedicated

receptacle and not in the storage

bin.

12MAdded

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10. System check Check temperature of inlet water

temperature.

Ensure that the warm exhaust is

not impinging directly on taps, pipes

or hoses supplying the cold water.

Record temperature in logbook.

Ice should not be allowed to

stagnate in an ice-making machine’s

storage bin, but should be changed

frequently.

12MAdded

Page 349 of 614

INSULATION

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INSULATION35-01 35-01 THERMAL INSULATION

WARNING: Insulation may contain asbestos. If Asbestos is suspected or you are unsure of the

material - STOP WORK - Broken Insulation is dangerous and if in doubt do not start work and inform

your supervisor and client. Work MUST NOT re-start until a Certifcate for safe working is recieved.

WARNING: Insulation may contain asbestos. If Asbestos is suspected or you are unsure of

the material - STOP WORK. Broken Insulation is dangerous and if in doubt do not start work and

inform your supervisor and client. Work MUST NOT re-start until a Certificate for safe working is

received. Refer to www.hse.gov.uk for detail.

Damaged and missing insulation can allow the surface temperature of equipment and pipework to

exceed Dew Point - thus allowing condensation to occur and in sub-zero process ice build up to occur.

Potentially this could result in slippery surfaces, cosmetic damage and fungal infestation or rotting of

susceptible materials.

When an insulating material, becomes wet, the air enclosures fill with water and, because water is a

better conductor than air, the conductivity of the material increases.

The thickness of Thermal insulation should be in accordance with BS 5422:2009

Other


4. Insulation

Jackets

Re-install any valve, flange or

similar fittings boxes / insulation

jackets that have been removed

and left off. Report any of these

missing.

12MAdded

5. Cladding Check all cladding to make sure it

has not been damaged / dented

[especially near step over points].

repair any damage or report if

unable to repair

12MAdded

1. Pipe lagging. Check for dampness and broken

condition

Broken and damp insulation

washers energy and should be

repaired as soon as possible.

12M 1. Pipe lagging. Check for dampness and broken

condition. Report on condition of all

insulation and coverings, paying

particular attention to integrity of

any vapour seals.

Broken and damp insulation wastes

energy and should be repaired as

soon as possible.

12MTechnical

2. Boiler lagging. Check for broken condition and

repair if necessary.

12M 2. Boiler lagging. Check for broken condition and

repair if necessary. Report on

condition of all insulation and

coverings, paying particular

attention to integrity of any vapour

seals.

12MTechnical

Page 351 of 614

LIGHTING

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The design and installation of lighting systems should be in accordance with the CIBSE Code for

Interior Lighting and to ensure that the design conditions are maintained, regular maintenance is

necessary. Failure to carry out that maintenance will lead to reduced lighting levels, lower efficiency

and energy wastage. It must be stressed that lighting is often a significant cause of energy wastage

through illuminations, poor controls and not using modern energy saving lamps.

The maintenance of lighting installations covers four main sectors, these are:-

Local wiring and cabling, i.e. at entry and/or exit of fitting or control.

Fittings including luminaries.

Lamps

Controls

Normally for wiring and cabling little maintenance is required unless alterations or temporary

arrangements have been made. For luminaires and fittings the cleanliness of the environment is an

important factor dictating the frequency of cleaning, dirty fittings and tubes cause loss of light with the

consequent effect on the efficiency of the work station and the accuracy of the work being carried out .

In a dirty environment frequent cleaning may be necessary.

In the case of lamps, bulbs or luminaires the manufacturers quote a rated life. The rated life is the

best average of life for a manufactured batch.

There is also another factor which may dictate replacement frequency and that is accessibility. Often it

is cost effective to replace lamps on a regular basis based on the recommended life of the lamps .

Clearly in certain situations such as a shop or hospital or where access is very difficult a regular

replacement schedule may be the most sensible option and this should be agreed with the client.

The environmental factors of the disposal of items must be considered together with the type of

replacement used.

Luminaires are usually placed high up in a building and consequently are not easily accessible. A risk

assessment and method statement should be carried out. Access by stepladders is not

recommended.

The design and installation of lighting systems should be in accordance with the CIBSE Code for

Interior Lighting and to ensure that the design conditions are maintained, regular maintenance is

necessary. Failure to carry out that maintenance will lead to reduced lighting levels, lower efficiency

and energy wastage.

Maintenance routines can improve lighting efficiency by using a regular programme of cleaning for

lighting diffusers and by replacing luminaires as they become less efficient with age . There may also

be advantages in replacing older type tubular fluorescent lamps with modern, improved efficiency

units with an equivalent lighting output. In a dirty environment more frequent cleaning will be

necessary.

The maintenance of lighting installations covers four main sectors, these are:-

A) Local wiring and cabling, i.e. at entry and/or exit of fitting or control. B) Fittings including luminaries.

C) Lamps D) Controls

Normally for wiring and cabling little maintenance is required unless alterations or temporary

arrangements have been made. For luminaires and fittings the cleanliness of the environment is an

important factor dictating the frequency of cleaning in a dirty environment frequent cleaning may be

necessary. Dirty reflectors, diffusers, lamps and tubes cause loss of light with the consequent effect

on the ‘task’ for which the luminaire was initially installed and the accuracy of the ‘task’ being carried

out. Most lamps should be changed at the end of their useful life which is usually before they fail.

While continuing to consume the same power as when new, a lamp’s output may decline by 50% or

more before it fails. Aim to replace SON and metal halide lamps as soon as they fail. The lamp igniter

will continue to try to restart the failed lamp. This can use more energy than if the lamp was working

normally and, in addition, puts strain on the ballast, causing it to fail in extreme cases.

Manufacturers quote a rated life for Lamps and Tubes.. The rated life is the best average of life for a

manufactured batch.

A note should be made where lamps with different colour temperatures are used in different parts of a

building to avoid a combination of colours in the same room. It is equally important to ensure that

lamps / tubes are replaced with like for like types of the correct colour rendition.

There is also another factor which may dictate replacement frequency and that is accessibility. Often it

is cost effective to replace lamps on a regular basis based on the recommended life of the lamps .

Clearly in certain situations such as retail store or hospital or where access is very difficult a regular

replacement schedule may be the most sensible option and this should be agreed with the service

provider.

The environmental factors of the disposal of items must be considered together with the type of

replacement used. Fluorescent tubes and other mercury containing discharge lamps together with low

and high pressure sodium lamps waste are now classified as hazardous under the Hazardous Waste

Regulations 2005. These regulations came into force 16th July 2005 in England and Wales replacing

the Special Waste Regulations 1996.

See Hazardous area (electrics) SFG 27 for any lighting works in explosive areas or where intrinsically

safe fittings are installed.

Other

Page 353 of 614

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LIGHTING-SWITCHES-INTERNAL AND EXTERNAL36-02 36-02 LIGHTING-SWITCHES-INTERNAL AND EXTERNAL


4.Solar operated

switches (external

and internal).

Clean detector surface.

Check:switching function,

12M 4.Solar operated

switches (external

and internal).

Clean detector surface. Check:

switching function,

12MOther

6.Automatic

switching controls

(e.g. timers).

Check operation and time settings. Adjustments for BST should be

made by the client on the

appropriate dates. For external

lighting regular adjustments should

be made to compensate for

changes in daylight hours. This will

reduce energy wastage.

12M 6.Automatic

switching controls

(e.g. timers).

Check operation and time settings. Adjustments for BST should be

made by the service provider on the

appropriate dates. For external

lighting regular adjustments should

be made to compensate for

changes in daylight hours.

6MOther

Page 354 of 614

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LIGHTING FITTINGS including LUMINAIRES general36-03 36-03 LIGHTING FITTINGS including LUMINAIRES general

Please see Lighting SFG 36-01 introductory procedures before commencing.

Wear cotton gloves on highly reflective luminaire diffusers and when changing tungsten capsule

lamps.



Added


1.Cleanliness. Clean fittings where necessary. Frequency of cleaning will depend

on environment, in dirty areas more


necessary. Contract should state

whether this is part of the

maintenance contract.

12M 1.Cleanliness. Check each lamp for build-up of

dust and dirt, clean as required.

Frequency of cleaning will depend



necessary.

12MTechnical

2.Lamps

a)tungsten

filament,

Check for failed lamps or signs of

deterioration.Replace as required.

Tungsten filament lamps are

inefficient with regard to energy use

and could be replaced with more

efficient lamp types.

12M 2.Lamps

a)tungsten

filament,

Check for failed lamps or signs of

deterioration. Replace as required.

12MOther

b)fluorescent, Clean and replace any failed or

suspect lamps.

Care should be taken in handling as

broken glass from broken

tubes/lamps can be

dangerous.Disposal of tubes/lamps

should be in accordance with H&S

and Environmental regulations.

12M b)fluorescent, Check for failed or flickering lamps

or signs of deterioration. Replace

as required



tubes/lamps can be dangerous.

Disposal of tubes/lamps should be

in accordance with H&S


shh/index.htm) and Environmental

regulations.

12MTechnical

8.Switches. Check operation. Replace if faulty.12M 8.Switches and

control contactors

Check operation of all switches.

Check function and operation of

any lighting control contactors;

ensure that lamp circuits operate at

correct times, both for normal

operation and for extended on/off

periods.

Replace if faulty.12MTechnical

Page 355 of 614

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EXTERNAL LIGHTING including ILLUMINATED SIGNS36-04 36-04 EXTERNAL LIGHTING including ILLUMINATED SIGNS

WARNING : Equipment may operate at voltages above 415 and extra precautions should be

taken.

Please see Lighting SFG 36-01 introductory procedures before commencing.

Wear cotton gloves on highly reflective luminaire diffusers and when changing tungsten capsule

lamps.



WARNING : Equipment may operate at voltages above 415v.

Added


External FittingsAdded

1. General Clean and check: For physical


condensation, if present check

seals and report toclient.

Check mounting

brackets/supports/columns etc., for

corrosion, damage and security,

report all findings

Frequency of cleaning will depend



necessary.

6MAdded

2. Lamps Check for failed or flickering lamps

or signs of deterioration. Replace

as required



tubes/lamps can be dangerous.

Disposal of tubes/lamps should be

in accordance with H&S and


12MAdded

3. Cable

connections

Check externally for security and

signs of arcing or overheating.

Renew or re-fix as necessary.12MAdded

4. Lamp control

gear.

Check operation and compatibility

with lamp.

12MAdded

5. Switches and

control contactors

Check operation of all switches.


any lighting control contactors;

ensure that lamp circuits operate at

correct times, both for normal

operation and for extended on/off

periods

Replace if faulty.12MAdded

6. Electrical wiring. Check integrity and report to client if

renewal necessary

12MAdded

7. Earth continuity Check and remedy if necessary.6MAdded

SignageAdded

Page 356 of 614

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1.Condition. Clean and check:For physical



seals and report to client.

On plastic surfaces avoid a build up

of static which will re-attract dirt.

Cleaning materials should be

compatible with sign fabric.If

evidence of need for re-painting

observed, notify client.

6M 1.Condition. Clean and check: For physical



seals and report to client.

On plastic surfaces avoid a build up

of static which will re-attract dirt.

Cleaning materials should be

compatible with sign fabric. If

evidence of need for re-painting

observed, notify client.

6MTechnical

4.Lamps or tubes. Check for failed or blackened tubes

or lamps. Replace as necessary.

Replacement procedures should be

agreed with the client as

recommended life can vary with type

of luminaire. Tube or lamp colour

should conform with original colour

specification. Disposal of tubes

should be in accordance with H&S

and Environmental regulations.

12M 4.Lamps or tubes. Check for failed or blackened tubes

or lamps. Replace as necessary.

Replacement procedures should be

agreed with the client as

recommended life can vary with

type of luminaire. Tube or lamp

colour should conform with original

colour specification. Disposal of

tubes should be in accordance with

H&S



regulations.

12MTechnical

6.Control gear. Check for correct operation. Replacement equipment should be

compatible with that removed.

Replacement cold cathode

transformers should be re-calibrated

to the design mA output.

12M 6.Control gear. Check for correct operation. Replacement equipment should be

compatible with that removed.

Replacement cold cathode

transformers should be re-calibrated

to the design mA output.

12MTechnical

Page 357 of 614

LIGHTING- EMERGENCY

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EMERGENCY LIGHTING self contained37-01 37-01 EMERGENCY LIGHTING self contained

Emergency lighting levels in existing installations may have to be upgraded to comply with current

legislation.

To be carried out in accordance with BS EN 50172:2004 / BS 5266 Part 8: 2004. All tests shall be

logged as section 6 of that document.

In addition to the tasks shown below;

The emergency lighting record logbook or monitoring system should be checked in order that

recorded faults may be rectified. All emergency and escape lighting systems should be inspected

daily.

In particular, it should be ensured that:

a) every lamp is lit if the system is maintained;

b) the control panel for any central battery system or generator

indicates normal operation; This is a visual inspection of indicators to identify that the system is in a

ready condition and does not require a test of operation.

c) any fault found is logged and the appropriate action(s) taken.

Because of the possibility of a failure of the normal lighting supply occurring shortly after a period of

testing of the emergency lighting system or during the subsequent recharge period, all full duration

tests shall wherever possible be undertaken preceding time of low risk to allow for battery recharge.

Alternatively, suitable temporary arrangements shall be made until the batteries have been recharged.

The following minimum inspections and tests shall be carried out at the intervals recommended below.

The regulating authority may require specific tests.

Technical


1.Testing. To be carried out monthly in

accordance with BS 5266:Part 1:

2005. All tests shall be logged as

per Appendix C of BS 5266.

Client s operators should be trained

to carry out monthly tasks.

1M 1.Test - Monthly If automatic testing devices are

used, the results of the short

duration tests shall be recorded.

Switch on in the emergency mode

each luminaire and each internally

illuminated exit sign from its battery

by simulation of a failure of the

supply to the normal lighting for a

period sufficient to ensure that each

lamp is illuminated.

During this period, all luminaires

and signs shall be checked to

ensure that they are present, clean

and functioning correctly.

At the end of this test period, the

supply to the normal lighting should

be restored and any indicator lamp

or device checked to ensure that it

is showing that the normal supply

has been restored.

The period of simulated failure

should be sufficient for the purpose

of this clause whilst minimising

damage to the

system components e.g. lamps.

Any luminaires or exit signs that do

not function correctly should be

repaired or replaced.

Responsibility for monthly check

should be agreed with the client.

1MTechnical

2.Operation. Check operation, if failure is

suspected replace lamp.

If fault is not with lamp check that

the mains LED is on with the mains

supply restored, if not, report to

client. Responsibility for monthly

check should be agreed with the

client.

1M Deleted

Page 359 of 614

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3.Battery. Check condition and date of

expected life. Renew if necessary.

Normal life expectancy is five years.

Batteries must be disposed of in


Environmental Regulations.

12M 3.Battery. Check condition and date of

expected life. Renew if necessary.

Normal life expectancy is five years.

Batteries must be disposed of in



12MOther

Test for one hour. If luminaire rated for duration of one

hour, test

6M 2. Test - Annually If automatic testing devices are

used, the results of the full rated

duration test shall be recorded.

For all other systems the monthly

inspection shall be carried out and

the following additional tests made:

each luminaire and internally

illuminated sign shall be tested as

per item 1 above [monthly] but for

its full rated duration

in accordance with the

manufacturer`s information;

The supply of the normal lighting

shall be restored and any indicator

lamp or device checked to ensure

that it is showing that normal supply

has been restored. The charging

arrangements should be checked

for proper functioning;

The date of the test and its results

shall be recorded in the system

logbook




The once per year test is for the full

duration of the battery.

12MTechnical

Test for three hours. The once per year test is for the full

duration of

12M Deleted

Page 360 of 614

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EMERGENCY LIGHTING externally powered37-02 37-02 EMERGENCY LIGHTING externally powered

Emergency lighting levels in existing installations may have to be upgraded to comply with current

legislation; the COSHH Regulations must also be followed - refer to www.hse.gov.uk for details.

To be carried out in accordance with BS EN 50172:2004 / BS 5266 Part 8: 2004. All tests shall be

logged as section 6 of that document.

In addition to the tasks shown below;

The emergency lighting record logbook or monitoring system should be checked in order that

recorded faults may be rectified. All emergency and escape lighting systems should be inspected

daily.

In particular, it should be ensured that:

a) every lamp is lit if the system is maintained;

b) the control panel for any central battery system or generator

indicates normal operation; This is a visual inspection of indicators to identify that the system is in a

ready condition and does not require a test of operation.

c) any fault found is logged and the appropriate action(s) taken.

Because of the possibility of a failure of the normal lighting supply occurring shortly after a period of

testing of the emergency lighting system or during the subsequent recharge period, all full duration

tests shall wherever possible be undertaken preceding time of low risk to allow for battery recharge.

Alternatively, suitable temporary arrangements shall be made until the batteries have been recharged.

The following minimum inspections and tests shall be carried out at the intervals recommended below.

The regulating authority may require specific tests.

Technical


Energise from battery for period of

one hour.

If the system is rated for one hour,

duration of test simulating failure

should be fifteen minutes.

6M 2) TEST -

Annually

If automatic testing devices are

used, the results of the full rated

duration test shall be recorded.

For all other systems the monthly

inspection shall be carried out and

the following additional tests made:

each luminaire and internally

illuminated sign shall be tested as

per item 1 above [monthly] but for

its full rated duration

in accordance with the

manufacturer`s information;

The supply of the normal lighting

shall be restored and any indicator

lamp or device checked to ensure

that it is showing that normal supply

has been restored. The charging

arrangements should be checked

for proper functioning;

The date of the test and its results

shall be recorded in the system

logbook.

Generator - In addition to the above

for generating sets, refer to the

requirement of ISO 8528-12




The once per year test is for the full

duration of the battery.

12MTechnical

Page 361 of 614

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Test for one hour. The once per year test is for the full

duration of the battery and is best

carried out when there is least risk

to persons in the building i.e. late on

Friday.

12M Deleted

1.Testing. To be carried out monthly is

accordance with BS 5266:Part 1:

2005. All tests shall be logged as

per Appendix C of BS 5266.

Client s operators should be trained

to carry out monthly tasks.

1M 1.Test - Monthly If automatic testing devices are

used, the results of the short

duration tests shall be recorded.

Switch on in the emergency mode

each luminaire and each internally

illuminated exit sign from its battery

by simulation of a failure of the

supply to the normal lighting for a

period sufficient to ensure that each

lamp is illuminated.

During this period, all luminaires

and signs shall be checked to

ensure that they are present, clean

and functioning correctly.

At the end of this test period, the

supply to the normal lighting should

be restored and any indicator lamp

or device checked to ensure that it

is showing that the normal supply

has been restored.

Central battery system - In addition

to the above for central battery

systems, the correct operation of

system monitors shall be checked.

Generator - In addition to the above

for generating sets, refer to the

requirement of ISO 8528-12.

The period of simulated failure

should be sufficient for the purpose

of this clause whilst minimising

damage to the

system components e.g. lamps.




Responsibility for monthly check

should be agreed with the client

1MTechnical

2.Operation. Energise from battery for period of

one hour.

If the system is rated for one hour,

duration of test simulating failure

should be fifteen minutes.

6M Deleted

3.Battery. Ensure terminals are clean and

check electrolyte level. Check

condition of battery case(s).

Follow manufacturer s instructions

at all times and advise client if

battery replacement is required.

6M 3.Battery. Ensure terminals are clean and

check electrolyte level. Check

condition of battery case(s).

In accordance with the

manufacturer’s requirements the

inspection should include a check

of;

voltage setting on the charger; cell

or monobloc battery voltages;

specific gravity (SG) and electrolyte

level, if appropriate; cleanliness,

leakage; tightness of connectors, if

required; ventilation; vent plugs or

valves; battery temperature.

Follow manufacturer s instructions

at all times and advise client if

battery replacement is required

6MTechnical

Page 362 of 614

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CHILLED WATER-CONDENSER WATER PIPE SYSTEMS40-04

Page 363 of 614

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CONDENSER - CHILLED WATER CIRCULATING PUMPS40-05

Page 364 of 614

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PRESSURISATION UNITS - CHILLED WATER40-06

Page 365 of 614

LIGHTNING PROTECTION

Page 366 of 614

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LIGHTNING CONDUCTOR AND EARTH38-01 38-01 LIGHTNING CONDUCTOR AND EARTH

(Does not cover lightning strike prevention.) All inspection, testing and documentation shall be carried out in strict accordance with BS EN 62305-

1 to 4 inclusive:2006

The inspection comprises checking the technical documentation, visual inspections and test

measurements. The object of the inspection is to verify that

– the Lightning electromagnetic pulse protection measures system (LPMS) complies with the design,

– the Lightning electromagnetic pulse protection measures system (LPMS) is capable of performing

its design function,

– any newly added protection measure is integrated correctly into the Lightning electromagnetic pulse

protection measures system (LPMS) .

Inspections shall be made; Periodically, after any alteration of components relevant to the system

and possibly after a lightning flash to the structure (e.g. where indicated by a lightning flash counter, or

where an eyewitness account of a flash to the structure is provided, or where there is visual evidence

of lightning-related damage to the structure).

The frequency of the periodical inspections shall be determined with consideration to

– the local environment, such as corrosive soils and corrosive atmospheric conditions,

– the type of protection measures employed.

Technical


1.Conductor tape

fastenings and

joints.

Inspect roof and plant connections,

vertical joint connectors and earth

termination positions. Ensure that

conductor tapes are secured firmly

to the structure and all joints

including those to structural and

service steelwork are mechanically

and electrically sound.

Look for evidence of corrosion in the

material, this is more likely to occur

where there is contact between two

dissimilar metals or where the

atmosphere has the potential for a

high degree of chemical pollution. If

renewal required, report to client.

12M 1.Conductor tape

fastenings and

joints.

A visual inspection shall be carried

out to verify that;

A) there are no loose connections

nor any accidental breaks in

conductors and joints, B) no part of

the system has been weakened

due to corrosion, especially at

ground level, C) bonding

conductors and cable shields are

intact, D) there are no additions or

alterations which require further

protection measures, E) there is no

indication of damage to the SPDs

[surge protection device] and their

fuses or disconnectors, F)

appropriate line routings are

maintained, G) safety distances to

the spatial shields are maintained

Look for evidence of corrosion in the

material, this is more likely to occur

where there is contact between two

dissimilar metals or where the

atmosphere has the potential for a

high degree of chemical pollution. If

renewal required, report as

neccessary

13MTechnical

2.Earth

terminations.

Test resistance to earth. Advise client if the whole of the

lighting protection system has a

resistance to earth over 10 ohms.

Record details and copy to client.

12M 3.Earth

terminations.

Test resistance to earth Advise client if the whole of the

lighting protection system has a

resistance to earth over 10 ohms.

Record details and copy as

neccessary.

13MOther

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3. Lightning

strike.

Record details and copy to client.

After evidence of lightning strike the

complete procedure for inspection

and testing should be carried out as

soon as possible to ascertain the

condition of the system.

4. Documentation

and report

The inspector shall prepare a

report, which shall be attached to

the technical documentation and

the previous inspection reports. The

inspection report shall contain

information covering

– the general status of the LPMS,

– any deviation(s) from the

technical documentation,

– the result of any measurements

performed

After inspection, all defects noted

shall be corrected without delay. If

necessary, the technical

documentation shall be updated

13MTechnical

2. Electrical

continuity tests

For those parts of an earthing

system and bonding network which

are not visible for inspection,

measurements of electrical

continuity should be performed

13MAdded

Page 368 of 614

MOTORS

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MOTORS- DRIVE ELEMENTS39-01 39-01 MOTORS- DRIVE ELEMENTS

Note: Before carrying out any work, check status and isolate in accordance with HASAWA and

Electricity at Work requirements. This may require the engineer to follow a permit to work system.

Dual motor systems should be treated as one.

Note: Before carrying out any work, check status and isolate in accordance with HASAWA

(www.hse.gov.uk) and Electricity at Work requirements. This may require the engineer to follow a

permit to work system. Dual motor systems should be treated as one.

Other


2. Motor casing. Check ventilating louvres are clear. See also MOTORS.3M 2. Motor casing. Check ventilating louvers are clear.3MOther

8. Variable speed

drives and other

solid state

controls.

Refer to manufacturer. Faults and any special maintenance

requirements should be referred to

the manufacturer as specialised

skills are needed to deal with this

type of equipment. See

CONTROLLERS Speed controllers.

12M 8. Variable speed

drives and other

solid state

controls.

Refer to manufacturer. Faults and any special maintenance

requirements should be referred to

the manufacturer as specialised

skills are needed to deal with this

type of equipment. See Controllers

SFG 14-15 speed controllers.

12MOther

Page 370 of 614

PIPEWORK SYSTEMS

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PIPEWORK SYSTEMS - General40-01 40-01 PIPEWORK SYSTEMS - General


1. Supports. Check and tighten as necessary. Loose supports can lead to undue

strain on pipework.

12M 2. Supports and

Brackets

Check and tighten as necessary.12MOther

2. Valves and

stopcocks (where

normally open)

Check operation. Valves should be

fully closed and then fully opened.

Lubricate as necessary.

N.B. Carefully note the number of

turns to fully close, so that valve can

be reset to its original position. If

operation of valve stiff, repeat

operation until clear and then return

valve to its original position.

12M 3. Valves and

stopcocks (where

normally open)

Check operation. Valves should be

fully closed and then fully opened.

Lubricate as necessary.

N.B. Carefully note the number of

turns to fully close, so that valve can

be reset to its original position. If

operation of valve stiff, repeat

operation until clear and then return

valve to its original position.

12MTechnical

3. Regulating

valves.

Do not adjust unless alterations or

additions to pipework have been

made.

If alterations to the pipework have

been made it will be necessary to

recommission the system.

12M 4. Regulating

valves.

Do not adjust unless alterations or

additions to pipework have been

made.

If alterations to the pipework have

been made it will be necessary to

recommission the system.

12MOther

4. Double

regulating valves.

Check operation. Settings should not be altered, but

they can be used for regulation.

12M 5. Double

regulating valves.

Check operation. Settings should not be altered, but

they can be used for regulation.

12MOther

5. Glands. Rectify any leakages. For severe leakage, immediate

emergency action will be necessary.

For regulating valve see action 3

above.

12M 6. Glands. Check all valves within pipework

run for gland leakage, where

possible at time of inspection adjust

or repack as required. Ensure

packing is the correct size and

material in accordance with

manufacturers recommendations

For severe leakage, immediate

emergency action will be necessary.

12MTechnical

6. Anchor points

and guide

assemblies.

Check for security of fittings.12M 12. Anchor points

and guide

assemblies.

Check for security of fittings.12MOther

1. General Check all pipework for signs of

leaks, if possible repair and stem

leak

12MAdded

7. Expansion

bellows

Check condition and alignment of

expansion bellows /compensators.

Report any defects.12MAdded

8. Sensors,

gauges, detectors

Ensure all pipeline mounted

detectors/sensors and gauges are

in good repair

12MAdded

9. Hit Hazards Inspect pipework run and where it

runs across or parallel to a

personnel access route. Highlight

any low points where heads could

be hit with the appropriate hazard

tape or paint

12MAdded

10. ID tags Check identification tags are

provided for all pipeline mounted

equipment, valves etc.

12MAdded

11. Insulation Report on condition of all insulation

and coverings, paying particular

attention to integrity of any vapour

seals

See Insulation SFG35-01.12MAdded

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PIPEWORK SYSTEMS-TRACE HEATING40-03 40-03 PIPEWORK SYSTEMS-TRACE HEATING


5. Controls. Check functioning of controls. For more detailed maintenance of

thermostats, frost protection etc.,

see relevant section.

12M 5. Controls. Check functioning of controls. For more detailed maintenance see

thermostats, frost protection etc.

12MTechnical

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PNEUMATIC EQUIPMENT – COMPRESSED AIR SYSTEMS40-07 40-07 PNEUMATIC EQUIPMENT – COMPRESSED AIR SYSTEMS

For efficient operation of air operated control equipment such as control valves , relays and actuators a

supply of clean dry, oil free compressed air is essential. Pipelines should be adequately sized to

minimise pressure loss and checked regularly for leakage as this can result in mal-operation and

energy wastage.

It should be noted that air receivers operating above 0.5 bar gauge pressure are subject to mandatory

periodical certification and no work should be carried out on an uncertified vessel and the client

informed of the position.

To comply with the Pressure Systems and Transportable Gas Containers Regulations 1989, a written

scheme of examination is required to be provided for the periodic examination of the whole system.

The written scheme must be drawn up by a ‘competent person’. Refer also to HSG39 Compressor Air

Safety.

Regular maintenance of the instrument air compressor is essential and particular attention should be

paid to the performance of the air drier and oil separator.

There are specific statutory requirements for the examination and maintenance of pressure systems

including air receivers (Users should be familiar with the statutory requirements applying to

compressed air systems and air receivers. These are principally contained in the Pressure Systems

and Transportable Gas Containers Regulations 1989. Additional recommendations are given in the

Approved Code of practice safety of pressure systems.). In addition to the specific requirements,

general requirements are set out in Section 2(2)(a) of the HSW Act and PUWER:

There are many ways in which compressed air can be dangerous, for example:

1. it can enter body orifices such as the mouth, ears and anus, causing severe and often fatal injuries:

2. at high pressure it can penetrate the skin;

3. particles or oil carried in an air jet can damage the eyes;

oil-coke deposits in a system can spontaneously ignite and cause an explosion;

4. vessels containing compressed air, even at comparatively low pressure, can explode violently once

their integrity is lost; and

5. dirty or `wet` air car, lead to corrosion and blocked valves which may make the system unsafe.

It should be noted that air receivers operating above 0.5 bar gauge pressure are subject to mandatory

periodical certification and no work should be carried out on an uncertified vessel and the client

informed of the position

Before any pressurised components are dismantled they should be effectively isolated from all

pressure sources and completely vented to atmosphere. Precautions should also be taken to guard

against the possibility of injury through sudden release of trapped springs.

When components, especially valves, are found to be worn and service kits of seals are used to

rebuild them, care should be taken to check thoroughly the function of the rebuilt valve before placing

it in the equipment. Incorrect seal replacement can completely alter the valve`s function and if

replaced in the equipment could present a serious hazardTechnical

Other

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AIR COMPRESSORS40-08 40-08 AIR COMPRESSORS AND RECEIVERS

WARNING - Where Nitrogen is used, a Risk Assessment must be done prior and suitable training

given. The breathing of Oxygen free Nitrogen can be fatal, ensure any discharge can not endanger

others.

It should be noted that to ensure dry, clean and oil free air, there are a number of daily and weekly

tasks which the plant operator must carry out as part of his duties. These include condensate

drainage, pressure drop checks across filters, oil contamination checks and audible leaks.

WARNING – All maintenance work, other than routine checks to filters designed for cleaning

in-service, should be undertaken only when the compressor has been stopped, disconnected and

locked off from the power supply and all internal pressure dissipated. Other precautions may also be

necessary: for example, the compressor may have to be scotched to prevent movement of the

mechanism.

Under no circumstances should flammable liquids by used for cleaning. Appropriate safety

precautions should be taken against any toxic vapours liberated during usage of any cleaning or

degreasing liquids.

It should be noted that to ensure dry, clean and oil free air, there are a number of daily and weekly

tasks which the plant operator must carry out as part of his duties. These include condensate

drainage, pressure drop checks across filters, oil contamination checks and audible leaks.

The major hazard associated with compressors is over pressurisation, which may arise from:

(a) a blocked outlet or some other restriction to flow:

(b) failure of automatic controls combined with low air consumption;

(c) compressor malfunction, e.g. over speeding;

(d) an external fire near the pressure system: and

(e) overheating and the build-up of carbonaceous deposits, both of which can lead to fires or

explosions. Although they are rare, fires and explosions can also occur as a result of oil or oil vapour

being ignited in the pressure system.

Where receiver is fitted with automatic condensate drain valve, check for correct operation. Where

manual valves are provided, drain condensate.

Dirty or `wet` air can cause a system to fail e.g. by causing fine particles of debris to agglomerate,

blocking safety related valves

Technical


1. Cooling Water. The cooling water should be

visually checked to make sure that

it is circulating properly by

observing the flow outlet or flow

indicator

1DAdded

2. Oil level. The level of the oil in the crank

chamber should be checked using

a dipstick, level gauge or other

device. Any excessive usage of

lubricating oil should be

investigated

1DAdded

3. Oil pressure Oil pressure should be checked1DAdded

4. Oil feed Check oil feed to the cylinders to

make sure that it is adequate but

not excessive. Oil consumption

should be recorded, as excessive

consumption can often lead to

explosions downstream of the

compressor

1DAdded

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5. Air pressure &

temperature

Check and record the outlet air

pressure and temperature.

1DAdded

6. General Check the compressor performance

by listening for any unusual noises

during running.

1DAdded

7. Defects Defects found should be rectified

and a record kept

1DAdded

8. Air receiver Any accumulation of oil and water

should be drained from the air

receiver, the intercooler, the

aftercooler and main supply pipes.

1DAdded

9. Safety valves Safety valves (where design allows)

should be checked by easing them

by hand.

1WAdded

10. Air filter. Inspect air filter, clean/replace as

found necessary.

The condition of the inlet air filters

should be checked and thoroughly

cleaned or replaced. The interval

between successive replacements

will be determined by local

circumstances but is, to a certain

extent, controlled by the capacity of

the filter and the cleanliness of the

atmosphere in the vicinity.

Where oil wetted viscous filters are

used, spare units should be

provided and excess oil should be

drained from the filter units for at

least four to eight hours before the

units are replaced, except where the

manufacturer advises otherwise

1MAdded

14b Oil Drain and change the lubricating oil

using recommended lubricating oil

12MAdded

20a

Delivery Ports and

pipework

Where oil coke deposits are liable

to occur, check the delivery ports

and pipework. Clean as required

The period between inspections can

be modified in the light of

experience gained from operating a

particular installation

6MAdded

24. VALVES

[various]

Check condition of the valves.

Inspect and clean the

non-return/unloader valve

assembly.

Remove and inspect the crankcase

breather valve

After each 2000 hours of running or

annually (whichever is the sooner)

12MAdded

25. cooler section Clean the intercooler and

aftercooler sections.



12MAdded

26. Radiator the radiator should be drained and

washed out



12MAdded

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27. Air Receiver Prepare for and assist with

insurance inspection.

The air receiver should be

thoroughly cleaned and examined

internally.

Frequency will be set by Insurance

inspector

24MAdded

1. Capacity Test. Pump up receiver from zero

atmospheric pressure to working

pressure and note time taken.

Any marked difference from the

manufacturers specification may

indicate leakage or compressor

faults.

12M 11. Capacity

Test.

Pump up receiver from zero

atmospheric pressure to working

pressure and note time taken.

Any marked difference from the

manufacturers specification may

indicate leakage or compressor

faults.

12MOther

2. General

Conditions.

Check the following: condition of

guards, interstage cooler drains,

bearers and holding down bolts,

hand operated valves, moisture

traps.

Check for tightness of glands and

seats.

12M 12. General

Conditions.

Check the following: condition of

guards, inter-stage cooler drains,

bearers and holding down bolts,

hand operated valves, moisture

traps. Clean down all external

surfaces.

Inspect air receiver; check all

valves, seals etc., operate correctly

Check for tightness of glands and

seats.

12MTechnical

3. Status. Switch off and isolate electricity. Note: Electrical isolation should be


HSAWA. Where receivers are

subject to Statutory Tests and

Examinations for purposes of

insurance, major overhauls should

coincide with such tests and

examinations.Any recommendations

made by the Insurance Inspector

must be completed before the

receiver is returned to service.

12M 13. Status. Electrical Check for satisfactory

operation of local electrical isolation

device (stoplock/isolator

Note: Electrical isolation should be


HSAWA (www.hse.gov.uk). Where

receivers are subject to Statutory

Tests and Examinations for

purposes of insurance, major

overhauls should coincide with such

tests and examinations. Any

recommendations made by the

Insurance Inspector must be

completed before the receiver is

returned to service.

12MOther

4. Oil. Note level and change using

recommended lubricating oil.

12M 14a. Oil. Check the quality of oil in the crank

case and, according to the


replace if necessary

600 hours or 3M (whichever is the

sooner)

3MTechnical

5. Belt and Drive. Check tension and condition of

belts and drives

Ensure spare belts are available.12M 15. Belts, Guards

and Drive.

Check condition, tension and

alignment of drive belts and pulleys.

Renew drive belts as necessary.

Check drive guard is in good repair

and securely fixed, providing

correct cover of all moving parts.

Change lubricant in motor bearings

Ensure spare belts are available.12MTechnical

6. Condensate

removal.

Check condensate drainage system

and clean as necessary.

Note: This should be checked daily

as part of the normal in house

maintenance procedures. The

condition of the condensate is an

indication of the condition of the

compressor. Waste Disposal

Regulations apply.

12M 16. Condensate

removal.

Check condensate drainage system

and clean as necessary.

This should be checked daily as part

of the normal in house maintenance

procedures. The condition of the

condensate is an indication of the

condition of the compressor.

12MOther

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7. Pressure relief

valve.

Operate and check valve for

condition, operation, setting and

leak tightness. Adjust if necessary.

12M 17. Pressure relief

valve and

protective devices

Test safety valve and where fitted,

LP relief valve.

The condition of protective devices

should be checked and tested to

determine that they operate

correctly.

Fusible pellets or complete plugs

should be replaced

12MTechnical

8. Air filter. Clean. Poor condition can indicate main air

intake problems.

12M Deleted

9. Electrical

connections.

Check and tighten all connections.

Check condition of wiring and

insulation.

For associated equipment, see

MOTORS, PUMPS, FANS.

12M 18. Electrical Examine and report condition of all


of all terminal connections and

check for satisfactory condition of

any flexible cables/conduits. Ensure

plant has adequate earth conductor

and bonding is secure. Take and

log motor current and compare with

nameplate details.

for associated equipment see;

Motors SFG 39-01

Pumps SFG 45-01

Fans SFG 20-01

12MTechnical

10. Gauges. Check operation. Defective gauges should be

reported with a recommendation

that they be replaced.

12M 19. Gauges. Check operation. Defective gauges should be

reported with a recommendation

that they be replaced.

12MOther

11. Pipes and

connections.


tightness. Tighten connections as

necessary.

With soldered or brazed joints,

these may have to be remade. To

prevent internal scaling use dry,

oxygen free nitrogen (OFN) during

the jointing process. WARNING -

The breathing of Nitrogen can be

fatal, a Risk Assesment must be

done prior to its use, suitable

training must also be given prior.

12M 20b. Pipes and

connections.

In the case of oil lubricated

compressors, the delivery valves,

ports and all the pipework, vessels

and fittings between the delivery

port and that point in the system

at which the air temperature can be

confidently expected to be below

80`C. should be inspected. Any

carbonaceous deposit should be

effectively removed;


tightness. Tighten connections as

necessary.

With soldered or brazed joints,

these may have to be remade. To

prevent internal scaling use dry,

oxygen free nitrogen (OFN) during

the jointing process.

12MTechnical

12. Controls. Check operation of pressure

switches and auto change over

solenoids.

12M 21. Controls. Check that the regulating system

operates correctly Check operation

of pressure switches and auto

change over solenoids. Check and

log settings of high limit pressure

switch (es)

12MTechnical

13. Offloaders,

mechanical and

electrical.

Check operation.12M 22. Offloaders,

mechanical and

electrical.


14. Main air

intake air quality.

Check air source for possible

contamination and dangerous

gases.

If air quality affected by location of

intake, report to client. Repositioning

may be necessary.

12M 23. Main air

intake air quality.

Check air source for possible

contamination and dangerous

gases.

If air quality affected by location of

intake, report to client.

Repositioning may be necessary.

12MOther

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AIR COMPRESSORS Compressed air dryers40-09 40-09 AIR COMPRESSORS Compressed air dryers

The chambers of air dryers are pressure vessels and should conform with PD 5500:2009

“Specifications for unfired fusion- welded pressure vessels” or to a standard providing equal integrity.

If means are provided for isolating the dryer (and it is good practice to provide means of isolation for

all equipment), either the chambers should be constructed to withstand the maximum pressure that

can be generated by the compressor or a suitable pressure reducing valve and a safety valve should

be fitted to prevent the safe working pressure of the chambers from being exceeded.

Where there is no means of isolating the dryer from a suitable safety valve, e.g. on the receiver, and

where non-return valves are fitted to the dryer outlet (to protect it from stored energy in the system),

no safety valves are needed.

Maintenance operations should only be conducted when the system has been shut down, isolated

and fully depressurised. All connections must be undone with care, paying particular attention to the

areas that become pressurised. Do not modify or adjust control settings. Check all connections for

leakage and secure seating. Ensure all loose parts are removed or secured to the dryer before

operation.

Added


2. Electrical

wiring and

conduits.

Check condition and contacts.

Make good as necessary.

12M 2. Electrical

wiring and

conduits.


2. Cleaning. WARNING - The breathing of

Nitrogen can be fatal, a Risk

Assessment must be done and

training given prior to use.

Where applicable, dismantle and

clean with dry oxygen free nitrogen.

Examine, test, refit or renew items

listed under notes.

Items:- Insert casing-felt

pads-perforated

discs-spring-gauzes-strainers-cotton

wool- U pin-external

casing-desiccant as directed.

3M 2. Cleaning. A risk Assessment must be done

and training given prior to use.

Where applicable, dismantle and

clean with dry oxygen free nitrogen.

Examine, test, refit or renew items

listed under notes.

Items:- Insert casing-felt

pads-perforated

discs-spring-gauzes-strainers-cotton

wool- U pin-external

casing-desiccant as directed.

3MOther

c) )Water

absorption type

continued

Deleted

4. Re-activation

drying time.

Time change-over period. Compare with manufacturer s

recommendation.

3M 4. Re-activation

drying time.

Time change-over period. Compare with manufacturer`s

recommendation.

3MOther

c) Compressed air

network

distribution

Note: The Pressure Systems and

Transportable Gas Containers

Regulations will apply to the

complete system.

e) Compressed air

network

distribution



Regulations will apply to the

complete system.

Other

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FUEL SUPPLY FOR LOW PRESSURE GAS (LPG) OR OIL40-10 40-10 PIPEWORK FOR LOW PRESSURE NATURAL GAS, LIQUEFIED

PETROLEUM GAS (LPG) OR OIL

The following tasks are to be carried out to all pipework within the designated areaAdded


1b) Pipework

Oil

Visible oil feed pipes should be

inspected annually. Check for

leaks. Check sleeves and physical

soundness. Check all ends are

suitably plugged/capped.

Ensure the fill point drip-tray is

clean, free of water, debris and oil

before and after any oil delivery.

Some Regional requirements mean

some systems should be pressure

tested every 5 years where there

are joints in the system or every 10

years where there are no joints. In

environmentally sensitive areas an

alternative is to have a ‘pipe within a

pipe’ system incorporating a leak

detection and alarm system

12MAdded

2 b) Valves

Oil

Check for soundness and leakage.

Check all fire valves for cut off in

the event of a fire alarm, fire or

overheating

12MAdded

1. Pipework. Check for leaks. Check sleeves and

physical soundness. Check all ends

are suitably plugged/capped.

12M 1a. Pipework -

LPG

Pipework, flanges and fittings

should be inspected for corrosion

and damage. Particular care should

be paid to pipework where it passes

through supports and

walls. Pipework supports should be

checked to ensure that they are

secure and in satisfactory condition.

Thermal insulation should be

inspected for damage. Suspect

areas should be removed to allow

inspection of the pipe.

Gas detector tests should be

carried out in areas where gas can

accumulate and linger, e.g.

enclosed spaces, ducts and voids

and around the pipework entry to

buildings. Gas detector tests may

also be carried out on joints and

over known routes of underground

pipework.

Leak detection fluid may be used to

check exposed joints for leakage.

Soundness and leakage tests may

be carried out as specified in BS

5482 part 1 or LPGA Code of

Practice 1 part 1 or Code of

Practice 22 as appropriate

LPG pipework may, under certain

conditions, deteriorate and could

eventually leak. Such a leak may

result in a fire or explosion if the

LPG accumulates and an ignition

source is present.

Do not forget hidden pipework

where access is provided.

Gas detection instruments having a

scale that can detect to less than

10% of the lower explosive limit of

the gas in air in the pipework should

be used.

Check lists should be used as an

aid to ensuring that inspection and

tests have been carried out in

accordance with the strategy.

The competent person should

review the outcome of the

inspection and make

recommendations for changes to

the strategy as required.

12MTechnical

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2. Valves Check for soundness and leakage. See also VALVES in relevant

section.

12M 2 a) Valves LPG Check for soundness and leakage.

Emergency control valves should

be checked for accessibility and

operation

See also Valves SFG 6112MTechnical

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STEAM SERVICES40-11 40-11 STEAM SERVICES

WARNING - A Risk Assessment is required, before work starts, if Asbestos is thought to be present

STOP WORK, close off the area. Work can NOT re-start until until a Certified Safe to work Certificate

is recieved. If Asbestos is found, follow the Regulations.

The following tasks are to be carried out to all pipework within the designated area.Technical


1. Hangers and

supports.

Check for breakages or damage. Undetected broken hangers can

lead to undue strain on pipes and

possible breakage or sagging which

can lead to waterlogging.

12M 2. Hangers and

supports.

Check for breakages or damage. Undetected broken hangers can

lead to undue strain on pipes and

possible breakage or sagging which

can lead to waterlogging.

12MOther

2. Valves and

flanges.

Check for leakage, replace packing

if necessary.

Where insulated, check valve boxes

for sign of dampness - there is

usually a small drainage hole at the

bottom of the flange or valve box.

Unchecked leakage wastes energy

and causes pipe corrosion.

12M 3. Valves, steam

valves and

flanges.

Check all valves within pipework

run for gland leakage where

possible at time of inspection adjust

or repack as required. Ensure

packing is the correct size and

material in accordance with

manufacturer’s recommendations.

Take all valves (excluding

regulating valves) through total

travel and return to correct position

Wisps of steam escaping soon lead

to bigger leaks which cause scoring

of stems and flanges leading to

early replacement

12Mtechnical

3. Insulation. Check for damage and loss of

protection. Renew if necessary.

Damage is often caused by ladders,

feet or emergency repairs - in open

air insulation can become

waterlogged and ineffective. N.B.

Asbestos Regulations may apply.

1M 4. Insulation. Check for damage and loss of

protection. Renew if necessary.

Damage is often caused by ladders,

feet or emergency repairs - in open

air insulation can become

waterlogged and ineffective.

Asbestos Regulations may apply.

See Insulation SFG35-01.

1MOther

4. Valves on

drain legs of

mains.

Check operation. If not working can lead to

waterlogging of steam mains, slow

start ups and overloading of steam

traps and poor heat transfer.

12M 5. Valves on

drain legs of

mains.

Check operation. If not working can lead to

waterlogging of steam mains, slow

start ups and overloading of steam

traps and poor heat transfer.

12MOther

5. Operation of

steam traps.


and sight glasses.

Faults can lead to steam wastage,

excessive condensate, poor heat

transfer in associated equipment

and energy wastage.

1M 6. Operation of

steam traps.

Inspect steam trap sets, ensure

correct function and operation,

check isolating valves shut off,

clean trap set strainers.

Faults can lead to steam wastage,

excessive condensate, poor heat

transfer in associated equipment

and energy wastage.

1MOther

6. Vents on

steam lines.

Check operation. Presence of air in steam reduces

efficiency of heat exchangers.

12M 7. Vents on

steam lines.

Check operation. Presence of air in steam reduces

efficiency of heat exchangers.

12MOther

7. Steam valves. Renew packing on stems and

flanges where necessary.

Wisps of steam escaping soon lead

to bigger leaks which cause scoring

of stems and flanges leading to

early replacement.

12M Deleted

8. Condensate

services.

Check for pressure of continuous

discharge of steam. If present

check steam trips.

Condensate if uncontaminated is

valuable and should not be allowed

to run to waste but should be

returned to the boiler if economical

to do so. Where this is not possible

or is contaminated, it must be taken

to a foul drain or soakaway.

1M 8. Condensate

services.

Check for pressure of continuous

discharge of steam. If present

check steam trips.

Condensate if uncontaminated is

valuable and should not be allowed

to run to waste but should be

returned to the boiler if economical

to do so. Where this is not possible

or is contaminated, it must be taken

to a foul drain or soakaway.

1MOther

1 General Check all pipework for signs of

leaks, if possible repair and stem

leak

Do not forget hidden pipework

where access is provided.

3MAdded

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10. Pressure

reducing devices

Check PRD valve(s) for correct

function and operation, log

upstream and downstream

pressures.

12MAdded

11. Expansion

bellows

Check condition and alignment of

expansion bellows /compensators.

Report any defects.12MAdded

12. Sensors,

gauges, detectors

Ensure all pipeline mounted

detectors/sensors and gauges are

in good repair

12MAdded

13. Hit Hazards Inspect pipework run and where it

runs across or parallel to a

personnel access route. Highlight

any low points where heads could

be hit with the appropriate hazard

tape or paint

12MAdded

14. ID tags Check identification tags are

provided for all pipeline mounted

equipment, valves etc.

12MAdded

Page 383 of 614

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40-12 FLASH STEAM VESSEL

If insulation looks damaged - stop work- this may be asbestos - appropriate action must be taken prior

to further works. If the insulation is known or certified not to be asbestos, continue as follows: -

Prior to carrying out the planned maintenance on the flash steam vessel, the pre-maintenance

procedure detailed below should be followed:

(a) At the entrance to the Plant room, stop and listen for a steam leak (high pressure steam will be




Before starting maintenance be sure that the equipment is not pressurised or hot.

If any of the socket connections are not being used, they must be closed with an appropriate carbon

steel plug.

Added


1. Vessel and

pipework

connections

Inspect for any leaks. The estimated lifetime under

satisfactory working conditions is 5

years ; after this period it is

recommended a wall thickness

examination is carried out using

appropriate inspection equipment.

Poor quality water or corrosive fluids

will reduce this period.

12MAdded

2. Check

insulation for

damage.



vessel is in the open air, can



regulations may apply.

12MAdded

3. Safety valveAdded

i. Safety valve -

Operational status.

Check by raising gagging lever to

discharge steam or air. Release

gagging lever to reseat. Check for

dirt or damage.

Check that discharge is to free

space or if piped, that pipe outlet is

not directed to personnel. Check

with insurance company for

frequency of mandatory checks.

3MAdded

ii. Safety valve -

Inspection

Strip down, overhaul and then

rebuild to comply with the

competent persons requirements

under the pressure regulations and

the written scheme of examination.

The competent person may require

additional testing on completion of

the rebuild.

12MAdded

4. Bursting discs

(if fitted).

Check condition, report. The competent person should be

contacted for the routine

replacement frequency for the

bursting discs.

12MAdded

Page 384 of 614

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5. Isolating

valve(s)

Added

i. Operational

status.

Check by rotating hand wheel

sufficiently to ensure freedom of

movement. When fully open, close

valve 1/2 turn to ensure valve does

not jam.

3MAdded

ii. Gland leakage. Ensure correct packing material is

used for the fluid in the pipeline

After installation or replacement

check for gland leakage daily for

one week. Early signs of slight

leaks are due to `bedding in` or

drying out and are usually cured by

tightening of gland nuts.

Continuous leakage can lead to

erosion or corrosion of the valve

stem.

3MAdded

3. Overall

condition.

Inspect for external deterioration

due to leaks at end flanges or

aggressive environment.

Leakage from end flanges can be

due to pipe strains, poor joints or

pipe supports.

12MAdded

6. Float &

thermostatic

steam trap

Added

i) test Test that steam trap is working Test methods include listening

devices, optical sight glasses,

temperature monitoring, and

ultrasonic techniques.

3MAdded

ii) Cleaning Clean , ensure float is not leaking

and check seat of trap. If damaged

renew seat.

12MAdded

Page 385 of 614

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40-13 EMERGENCY SOLENOID FUEL VALVES


1. Emergency

Solenoid Fuel

Valves

Check operation and function of

emergency shut-off valves. Ensure

100% shut-off. Check valve

operation at each emergency

shut-off device (knock-off,

electro-thermal link, fire detector

etc.).

Ensure valve(s) is reset after

maintenance.

3MAdded

Page 386 of 614

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40-15 PRESSURE REDUCING VALVES




Added


Steam pressure

reducing valves

The written scheme of examination

may require the valves to be

stripped down, overhauled and then

rebuilt to comply with the Competent

Persons requirements under the

Pressure Regulation. If this is the

case it would make the task red.

Added

1. General

operation

Check unit operates without undue

noise or vibration.

3MAdded

2. Pipework Check all pipework supports are

secure.

3MAdded

3. Strainer and

steam traps

Remove, examine and clean

upstream strainer. Check operation

of all steam traps

3MAdded

4. Main valve

seat and valve

head.

Isolate and reduce pressure to

zero. Remove screen and clean,

clean gasket faces and renew

gasket.

The actual maintenance

requirements may vary with the type

of valve and the manufacturer`s

instructions should be followed

carefully.

12MAdded

5. Pilot valve

chamber

assembly.

Isolate and reduce air pressure to

zero. Check dimensions of plunger

gap and adjust if necessary.

The dimension of the plunger gap is

critical and it may be necessary to

grind or machine the top of the

plunger.

12MAdded

6. Pilot and main

diaphragms.

Thoroughly clean upper and lower

diaphragm chambers, ensure

contact faces are clean and

reassemble.

When refitting diaphragms make

sure that they are replaced the

same way round as when they were

removed.

12MAdded

Page 387 of 614

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40-16 WATER BUFFER/SURGE TANKS

In the context of Building Services the term surge or buffer tank is used to describe a closed vessel

which is used to increase the volume of LTHW or Chilled Water in a system and may be designed in

accordance with the Pressure Equipment Directive 97/23/EC.

This section covers the maintenance of the buffer tanks including mountings but is not intended to

cover the opening up of tanks for statutory insurance inspection (where required) which requires a

separate procedure, which may be carried out at the same time as the maintenance.

In accordance with good practice the operator should carry out a visual inspection of the buffer tank at


Prior to carrying out the planned maintenance of the buffer tank, the pre-maintenance procedure be

followed:



(b) Inspect buffer tank insulation and/or shell for signs of damage.




Added


1. Air Vents Where fitted check the operation of

the automatic air vent. Where

Manual vents are fitted open until

water is seen then close the vent

If buffer tank was in use, the water

may be hot and can be under

pressure, so care must be taken in

carrying out this item of the

schedule.

1MAdded

2. Drain

valve/drain cock



If buffer tank was in use, the water

may be hot and can be under

pressure, so care must be taken in

carrying out this item of the

schedule.

6MAdded

3. Thermostats,

pressure sensors,

altitude gauges

and thermometers.



masters.

12MAdded

4. internal

surfaces of shell

and sacrificial

anode.

Isolate the buffer tank from the

system, drain down , remove


scale formation and

corrosion.Where fitted, Check

status

Replace as necessary.

The calorifier will have to be drained

and opened up before the anode

can be inspected, therefore it

cannot be a pre-maintenance check

12MAdded

5. Put back into

operation

Refit all manhole covers, refill and

vent off air as required

12MAdded

Page 388 of 614

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40-17 WATER MAINS - above ground


1. Water Mains Check external water main for signs

of leaks, damage or deterioration of

pipework and supports.

6MAdded

2. Valves Rotate isolation valves through one

complete turn to detect leakage via

valve spindle stuffing box . When

fully open, close valve 1/2 turn to

ensure valve does not jam.

6MAdded

3. Insulation Ensure valves and pipework are

properly protected / insulated.


4. Filter Remove and clean water main inlet

filter.

6MAdded

5. Manhole Covers Ensure manhole covers are in

position and are free from

mechanical damage.


Page 389 of 614

PNEUMATICS

Page 390 of 614

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PNEUMATIC RELAYS41-01 41-01 PNEUMATIC RELAYS

Electric to pneumatic, pneumatic to electric and pneumatic to pneumatic. Electric to pneumatic, pneumatic to electric and pneumatic to pneumatic.

Before any pressurised components are dismantled they should be effectively isolated from all

pressure sources and completely vented to atmosphere. Precautions should also be taken to guard

against the possibility of injury through sudden release of trapped springs.

If relays are found to be worn and service kits of seals are used to rebuild them, care should be taken

to check thoroughly the function of the rebuilt relay before placing it in the equipment. Incorrect seal

replacement can completely alter the function and if replaced in the equipment, could present a

serious hazard

Technical


1. Input signal(s). Check. 6M 1. Input signal(s). Check.6MOther

2. Output

signal(s).

Check. By CONTROLS SPECIALIST6M 2. Output

signal(s).

Check.6MOther

3. Operation. Check for correct relationship

between input and output signals.

6M 3. Operation. Check for correct relationship

between input and output signals.

6MOther

Page 391 of 614

PORTABLE EQUIPMENT

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PORTABLE EQUIPMENT PAT TESTING42-01 42-01 PORTABLE APPLIANCE TESTING (PAT)

It is a requirement of the Electricity at Work Act 1989 (Regulation 4(2)) that portable electrical

equipment must be tested regularly (PAT testing) and records kept and equipment identified and

marked accordingly. See also ECA document, ref. P119204. Dependant on location the frequency

may be increased to 24m or more.

It is a requirement from April 1st 1990 the Electricity at Work Regulations 1989, in particular

Regulation 4(2), that "all systems shall be maintained so as to prevent, so far as is reasonably

practicable, danger" . Portable electrical equipment must be tested regularly (PAT testing) and records

kept and equipment identified and marked accordingly. See also ECA document, A GUIDE ON HOW

TO INSPECT AND TEST PORTABLE APPLIANCES SAFELY AND EFFECTIVELY.

The term `portable appliance` can be considered to be an appliance that is intended to be moved

while in operation or an appliance which can easily be moved from one place to another while

connected to the supply, e.g. vacuum cleaner, drill, hair dryer.

The intervals between both inspection and testing can be determined initially by assessing the risk

(the likelihood of danger arising), and will vary with the type of equipment, usage, and the nature of

the environment in which it is used. Also, the age of the equipment and previous test results need to

be considered. The frequency of inspection can be determined by experience and will generally be

more frequent than testing. More onerous conditions will demand more frequent inspection and testing

while less onerous conditions (and good inspection and test results) can lead to a reduced frequency.

The examples below follows the recommendations given in the IEE`s Code of Practice for In-Service

Inspection of Electrical Equipment and can be used until sufficient experience is built up to establish

what is appropriate to the circumstances.

1) Equipment hire external visual inspection – before and after return, full inspection & electrical

testing – before issue [unless earlier inspection indicates immediate testing is necessary.]

2Construction external visual inspection – before initial use and then 1 month, full inspection &

electrical testing – 3 months [unless earlier inspection indicates immediate testing is necessary.]

3) Industrial external visual inspection – before initial use and then 1 to 3 months, full inspection &

electrical testing – 6 – 12 months [unless earlier inspection indicates immediate testing is necessary.]

4) Commercial / Office external visual inspection – 6 months - 2 years, full inspection & electrical

testing – 6 months – 4 years [unless earlier inspection indicates immediate testing is necessary.]

5) Premises used by the public e.g. Hotels external visual inspection – 6 months - 2 years, full

inspection & electrical testing – 12 months – 4 years [unless earlier inspection indicates immediate

testing is necessary.]

6) Schools external visual inspection – 4 months – 1 year, full inspection & electrical testing – before

issue 12 months – 4 years [unless earlier inspection indicates immediate testing is necessary.]

N.B. For full details of tests to be carried out reference should be made to the IEE`S Code of Practice

technical


1. Plug tops. Examine for: cracks, loose

terminals, reverse polarity,

tightness of cord grip, correct fuse,

earthing and bonding, loose tops,

any other defect.

Note: Details must be entered on

the portable appliance test register.

Where plug tops are accessible by

children, the use of shrouds on the

plug top pins is mandatory. Note

and report the use of any extension

leads or multi-way adapters. Client

should be encouraged to make

monthly checks.

12M 1) Mains Lead a) visual inspection

(b) mains plug for cracks, loose

terminals, reverse polarity,

tightness of cord grip, correct fuse,

earthing and bonding, loose tops,

any other defect

.

Pass condition: two layers of

insulation; BS colours; no damage;

correctly connected; cable clamp

gripped to sheath; correct fuse fitted

Where plug tops are accessible by

children, the use of shrouds on the

plug top pins is mandatory. Note

and report the use of any extension

leads or multi-way adapters. Client

should be encouraged to make

monthly checks.

0MTechnical

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2. Cables. Examine flexible cables for wear,

fraying braids and brittle insulation.

Check colour coding.

If replacement necessary, report to

client.

12M 2a) Detachable

mains lead

(a) visual inspection of equipment

male connector

(b) attempt to open socket without

tool

(c) attempt to pull socket cable from

female connector

(d) polarity of 3-pin units

Pass condition

BS type or equivalent

Unopenable

no movement

as per BS 4491

0MTechnical

3. Detachable

mains lead.

Check electrical condition and

security of attachment.

12M 2b)

grommet/clamp

around mains lead

(a) inspection of grommet

(b) sharp pull on cable

(c) rotation of cable

Pass condition

cable insulation protected

no appreciable movement

no rotation

0MTechnical

4. On-off switch. Inspect and check action.12M 4) Conducting

Case (a) visual inspection

b) resistance of earth connections

between plug and equipment.

(c) high voltage insulation 500V dc

minimum test

Pass condition

correct operation; no damage

earth resistance 0.1 ohms and

resistance of supply cable. Earth

resistance 0.5 ohms for luminaires

including resistance of the supply

cable

Insulation resistance of 0.5 M ohms

for

a Class 1 appliance and 1.0 M ohms

for

a class II appliance

0MTechnical

5. Insulating

case.

Inspect and check for damage. If double insulated, makers mark

should be visible, if in doubt carry

out flash test. Note: All double

insulated equipment must be tested

at least once every four years.

12M 5) Insulating case visual inspection Pass condition

maker`s double insulation mark

visible; case undamaged

If double insulated, makers mark

should be visible, if in doubt carry

out flash test. Note: All double

insulated equipment must be tested

at least once every four years

0MTechnical

6. Accessible

fuse holders.

Inspect and check rating.12M 6) Accessible fuse

holders

visual inspection

Pass condition

no damage removal of carrier does

not permit live [Live at more than

50V in use] part to be touched

0MTechnical

7. Exposed

output

connections.

Check condition, for outputs greater

than 50V test short circuit current.

Short circuit currents should be less

than 5mA, if greater than 5mA,

equipment must be labelled

Unsuitable for use by children where

GS23 of the Electricity at Work

Regulations 1989 applies.

12M 7. Exposed

output

connections.

Check condition, for outputs greater

than 50V test short circuit current.

Short circuit currents should be less

than 5mA, if greater than 5mA,

equipment must be labelled

Unsuitable for use by children where

GS23 of the Electricity at Work

Regulations

0MTechnical

Equipment HireAdded

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a). external visual

inspection

Frequency: before and after return0MAdded

b). full inspection

& electrical testing

Unless earlier inspection indicates

immediate testing is necessary.

Frequency: before issue0MAdded

ConstructionAdded

a). external visual

inspection

Frequency: before initial use and

then 1 month

0MAdded

b). full inspection




3MAdded

IndustrialAdded

a). external visual

inspection

Frequency: before initial use and

then 1 to 3 months

0MAdded

b). full inspection




Frequency: 6M-12M0MAdded

CommercialAdded

a). external visual

inspection

Frequency: 6 months - 2 years0MAdded

b). full inspection




Frequency: 6 months – 4 years0MAdded

Premises used by

public e.g. hotels

Added

a). external visual

inspection

Frequency: 6 months - 2 years0MAdded

b). full inspection




Frequency: 12 months – 4 years0MAdded

SchoolsAdded

a). external visual

inspection

Frequency: 4 months – 1 year0MAdded

b). full inspection




Frequency: before issue 12 months

– 4 years

0MAdded

Page 395 of 614

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Testing For full details of tests to be carried

out reference should be made to

the IEE`S Code of Practice

For frequencies see examples

above

Added

3) Mains on/off

switch either 4 or

5, and 6

(a) visual inspection Pass condition

correct operation; no damage

0MAdded

8) Labels After each item of equipment is

tested mark it individually indicating

if it has passed or failed, the date of

the test and the date of the next

re-test

0MAdded

9) Log sheet The details of the tests and results

shall be recorded onto a log sheet,

suitable for recording the

information obtained from the test

and inspection carried out on that

item of equipment.

Check to ensure that the details

entered on the test label, fixed to

the equipment, tally with those

entered on the log sheet.

It is of paramount importance that a

record of maintenance, including

test results, is maintained

throughout the life of each item of

equipment. The provision of these

records will demonstrate that testing

has been carried out to an adequate

standard, and any difference

between subsequent tests can be

noted. Should these tests show a

deterioration in any part of the

equipment, remedial action is

necessary to ensure that danger

does not arise.

0MAdded

Page 396 of 614

POWER GENERATORS

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Many premises have standby power generation equipment to provide back up in the event of

incoming power failures and there has been a tendency to 'fit and forget' with the result that the

equipment may fail to operate just when it is needed. Regular maintenance and testing is therefore

essential and should form part of any maintenance schedule. These units comprise a mechanical

prime mover, usually an oil or gas powered internal combustion engine, an electrical generator with

associated equipment and may include mains synchronisation. This specification covers primarily the

electricity generation and control equipment and except for simple tasks, the maintenance of the

prime mover should be carried out by specialist contractors.

A similar position arises with small scale combined heat and power units which are being introduced to

many sites, here the equipment can be divided into three sections, the prime mover, electrical

generation and heat recovery. This section covers the electrical generation equipment and the

equipment used for utilising the recovered heat is covered within HEAT EMITTERS. Again the prime

mover should be maintained by specialist firms.

Many premises have standby power generation equipment to provide back up in the event of

incoming power failures and there has been a tendency to `fit and forget` with the result that the

equipment may fail to operate just when it is needed. These units comprise a mechanical prime

mover, usually an oil or gas powered internal combustion engine, an electrical generator with

associated equipment and may include mains synchronisation. This specification covers primarily the

electricity generation and control equipment and except for simple tasks, the maintenance of the

prime mover should be carried out by specialist contractors.

A similar position arises with small scale combined heat and power units which are being introduced to

many sites, here the equipment can be divided into three sections, the prime mover, electrical

generation and heat recovery. This section covers the electrical generation equipment and the

equipment used for utilising the recovered heat is covered within Heat emitters SFG28. Again the

prime mover should be maintained by specialist firms.

Generating plant, in particular the engine system requires regular attention to ensure reliability,

optimum performance and long life. All maintenance procedures should be fully in accordance with

the generator set operating and maintenance instructions. A maintenance log book should be

established upon accepting the plant after commissioning. This should include a full record of

hours-run readings and a summary of all servicing and repairs carried out, together with fuel and

lubricating oil consumption totals.

Whatever the mode of operation, the generating plant must operate when called upon to do so.

Failure of the battery starting system will prevent the generator set starting and hence this needs

regular and frequent checking. Periodic maintenance recommendations from the supplier will normally

cover routine checks on a frequent basis (possibly after 100 hours of use or at monthly intervals)

depending upon various operating factors. More detailed maintenance, including replacement of items

such as lubricants, filters, belts and coolant, can be expected every, say, 500 hours. Major

maintenance activities are required typically after 5000 hours. This may involve a complete strip-down

of the engine, and inspection and replacement of worn or defective parts

Other

Page 398 of 614

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POWER GENERATION--STAND-BY GENERATOR43-02 43-02 POWER GENERATION--STAND-BY GENERATOR

Frequent running and testing of stand-by power generation equipment is essential to ensure

immediate availability at time of need. It is recommended that plant should be run on load for a

minimum of four hours on a regular basis, or as required by Client..

Frequent running and testing of stand-by power generation equipment is essential to ensure

immediate availability at time of need. It is recommended that plant should be run on load for a

minimum of four hours on a regular basis, or as required by client.

Other


10. Drive Belts Check belts for slackness,

alignment or wear, adjust as

necessary.

6MAdded

11. Battery

Charger

Check condition of battery charger,

inspect for damage. Open and

check on condition of wiring and

transformer insulation. Check on all

electrical connections, clean or

blow out. Test operation of any

ON/OFF or selector switches, test

accuracy of meters. Inspect or

renew if damaged any flying leads,

terminals or clips. Take insulation

and earth impedance test.

6MAdded

12. Anti freeze Add anti-freeze to cooling system or

check specific gravity as applicable

6MAdded

13. Fuel Filter Change the fuel filter element and

clean the filter bowl.

6MAdded

14. Air intake

grilles - alternator

Check that air intake grilles on

alternator are clean and

unobstructed. Remove cover from

non-drive and remove any fluff or

dirt that may have accumulated

around diode plates and exciter

assembly.

6MAdded

15 a) Electrical Check all electrical connections for

security. Examine brush gear in the

dynamo and starter and clean

commutator, renew brushes as

necessary.

Check operation of low oil and high

coolant shutdown switches

6MAdded

Page 399 of 614

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15 b) Electrical Open all composite control panels

and associated switchgear. Clean

out interior of all panels. Inspect all

wiring for condition. Inspect all

terminations for security and

overheating. Visually check that an

efficient earth is being maintained.

Open, inspect and clean any

changeover switches on emergency

supply system. Check overloads

are functional and are set to correct

value. Ensure fuses of correct size

and type are fitted. Examine all

contacts for arcing and pitting,

dress or replace contacts as

applicable. Lightly lubricate all

contact faces with pure petroleum

jelly. Check relays for correct

function, replace any defective

components. Examine

switch-blades in isolators, ensure

they are free to move. Lubricate

pivots lightly with grease, ensuring

no grease comes into contact with

a conducting surface. Check for

smooth operation and that switches

are clearly marked. Before carrying

out the following test disconnect L.

V. circuits, i. e. rotating rectifier

diodes and A. V. R. circuits etc.

Carry out the following test:- a.

Insulation Resistance Test on

alternator and wiring. A figure of 1

megohm or above is acceptable. b.

Earth Loop Impedance Test on

alternator frame. Supply voltage =

Maximum allowed 3 X rating of

Fuse in amps, impedance in ohms

12MAdded

16. Operation and

auto-change

facility (where

applicable).

Check engine starter and solenoid

for good strong operation.

Check operation and starting

sequence.

6MAdded

17. Instruments Check that instruments are

functioning correctly and that glass

is clean.

6MAdded

18. Fuel transfer

pump

Check operation12MAdded

1.Condition. Visually inspect for oil leaks, loose

guards etc. Check: coolant level, oil

level,

These checks should be carried out

monthly by client's operators.

6M 1. General Visually inspect for oil leaks, loose

guards etc. Check: coolant level, oil

level,

These checks should be carried out

monthly by client`s operators.

1MTechnical

Page 400 of 614

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2.Drive belts. Check fan and alternator drive belts

for wear, tension and alignment.

6M 2. Oil Check oil in sump using the dipstick

and top up oil if necessary

Ensure correct grade and type of oil

used in accordance with


1MTechnical

3.Shut down

switches.

Check operation of low oil and high

coolant shutdown switches.

6M 3. Oil Filter and oil Change oil filter elements and clean

oil filter bowls. Drain the sump and

refill with fresh clean oil. Check

operation of sump heater.

Ensure correct grade and type of oil

used in accordance with


6MTechnical

4.Low water

switch.

Check operation.6M 4. Coolant Check water level in the radiator,

top up if necessary. Check

operation of low water switch

pH (acidity) and S.G. (specific

gravity) should be checked regularly

by the operator.

1MTechnical

5.Coolant. Check coolant level. pH (acidity) and S.G. (specific

gravity) should be checked regularly

by the operator.

6M 5. Fuel tank Check that fuel tank is full Top up as required1MTechnical

6.Injector pump

drive belts.

Check wear and tightness.12M 6. General Run engine and check that oil

pressure is correct, if not trace and

repair fault. Check the electrical

output on the generator control

panel. Examine for any leaks of

coolant, fuel or lubricating oil, rectify

as necessary

Where practicable, generator should

be started under mains failure

conditions.

Run generator on load for 6 hours

per month. Test run should be at

least 50% load for a minimum of 2 -

4 hours

1MTechnical

7.Operation and

auto-change

facility (where

applicable).

Check operation and starting

sequence.

12M 7. Starter battery Check starter batteries are fully

charged. Top up with distilled water

as necessary. Inspect cells ensure

that vent holes in filter caps are

clear. Check that conducting bars

and cable connections are clean

and tight, any trace of verdigras to

be cleaned off and connections to

be coated with petroleum jelly. Take

random test or specific gravity and

cell voltage.

A battery should be fully discharged

and re-charged every six months.

Charge batteries as necessary (in

accordance with instructions in

operating log). Top up electrolyte

using pure distilled water, ensure

that cells are gassing freely whilst

charging. Charge batteries to 1250

s. g. and 2. 1 volts per cell, or

otherwise as specified. Re-check

specific gravity.

a. Electrolyte should be kept to 12

mm above plates, only pure distilled

water to be used for this purpose. b.

Topping up should be carried out

before charging to ensure good

mixing. c. Ventilation holes in filter

caps must be kept clean. d. A lead

acid battery is fully charged when s.

g. is 1250 and all cells are at 2. 4

volts. The battery cells should not

be allowed to fall below 1150 s. g. or

1. 8 volts. e. When the charging rate

is in doubt, a long slow charge is

better than a short sharp one

1MTechnical

8.Sump heater. Check operation.12M 8. Breather and air

cleaners

Examine and clean if necessary6MTechnical

Page 401 of 614

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9.Fuel transfer

pump.

Check operation.12M 9. Bearings and

moving parts

Lightly grease the water pump

bearings and the clutch and power

take off bearings (if fitted).

Check all moving parts for smooth

operation, lubricate any pivoting

spindles as necessary.

.

6MTechnical

19 Load Bank

Testing

Carry out a load test of the

generator including a 110%

overload and 50% drop test

Load Bank Testing – It should be

reviewed and decided why do this

type of testing and what are its

benefits, versus the risks of not

doing this type of testing.

1) Can the facility`s critical load be

taken off line or placed onto a

generator backup in order to have

this type of testing performed?

2) Where will the load banks be

staged? What type of heat will be

generated and how will the added

heat affect the building? When

doing large system tests there will

be a large amount of heat

generated and that can affect

sprinkler systems if the load banks

are staged inside of the building.

3) Are doors going to have load

bank cables ran through them so

that the doors can not be locked or

used for normal use, this may

require extra security personnel

during testing?

In addition, on some older systems

it can make perfect sense to do a

system test with load banks in order

to re-calibrate the system and the

modules. On some of these older

systems that use calibration

potentiometers, these

potentiometers can drift out of

calibration over the years and by

performing a recalibration it will

insure that the system is operating

at peak performance

24MAdded

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BATTERIES - LEAD ACID - unsealed43-03 43-03 BATTERIES - LEAD ACID - unsealed

Caution: Lead acid batteries give off inflammable gases which can be explosive in confined spaces

therefore battery spaces must be well ventilated. Extinguish all naked lights before entering and no

smoking; PPE will be required. Refer to the COSHH Regulations for details - www.hse.gov.uk

Note This section is based on the requirements of the Code of Practice BS 6133 and all tools used for

maintenance must be insulated.

Caution: Lead acid batteries give off inflammable gases which can be explosive in confined spaces

therefore battery spaces must be well ventilated. Extinguish all naked lights before entering and no

smoking; PPE will be required. Refer to the COSHH Regulations for details - www.hse.gov.uk

Safety requirements for secondary batteries and battery installations BS EN 50272-2:2001 and BS EN

50272-1:2010 Safer Batteries

Legislative


1. Cells. Test and record specific gravity of

electrolyte and top up if necessary.

Cells should normally be checked

on a monthly basis.Cell and

connector covers should be

replaced immediately work is

completed.

12M 1. Cells. Test and record specific gravity of

electrolyte and top up if necessary.

Check cell or monobloc battery

voltages

Cells should normally be checked

on a monthly basis. Cell and

connector covers should be

replaced immediately work is

completed.

1MLegislative

5.Ventilation. Check that ventilation of battery

space is adequate.

Report to client if remedial action is

required.

12M 5.Ventilation. Check that ventilation of battery

space is adequate, working and

clear of blockages etc.

Report to client if remedial action is

required.

12MOther

7. Battery charger Check voltage setting on the

charger

1MAdded

8. Vent plugs or

valves

Check6MAdded

9. Battery Check temperature of battery6MAdded

10. General Check for cleanliness and leakage1MAdded

Page 403 of 614

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BATTERY CHARGING EQUIPMENT43-04 43-04 BATTERY CHARGING EQUIPMENT


1. Condition. Check all external and internal dust

from the equipment. Check

paintwork for damage or corrosion,

clean and repaint as

necessary.Check security of door

fastenings and lock.

All ventilation holes and slots should

be clear to prevent overheating.

Cause of corrosion should be

determined.

12M 1. Condition. Check all external and internal dust

from the equipment. Check

paintwork for damage or corrosion,

clean and repaint as necessary.

Check security of door fastenings

and lock.

All ventilation holes and slots should

be clear to prevent overheating.

Cause of corrosion should be

determined.

12MOther

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UNINTERRUPTIBLE POWER SUPPLIES43-05 43-05 UNINTERRUPTIBLE POWER SUPPLIES

Because of the vital nature of uniterruptible power supplies the frequency of maintenance should be

agreed with the client, a minimum frequency of at least six months is recommended. It is emphasised

that this is specialist equipment which should be maintained strictly in accordance with the

manufacturer's instructions

As this equipment is for use in emergencies, check with client that it is safe to proceed with

maintenance.

Because of the vital nature of uninterruptible power supplies the frequency of maintenance should be

agreed with the client, a minimum frequency of at least six months is recommended. It is emphasised

that this is specialist equipment which should be maintained strictly in accordance with the

manufacturer`s instruction

As this equipment is for use in emergencies, check with client that it is safe to proceed with

maintenance.

Technical


1. Cubicle. Check condition and clean, check

integrity of doors and panels,

including locks, Check for ease of

operation of switches, isolators and

circuit breakers, Check condition of

contractors see POWER

SUPPLIES.

All dirt and foreign bodies should be

removed.

6M 1. Cubicle. Check condition and clean, check

integrity of doors and panels,

including locks, Check for ease of

operation of switches, isolators and

circuit breakers. Check condition of

contactors see Power supplies

SFG44.

All dirt and foreign bodies should be

removed.

6MTechnical

5. Rectifier. Switch on and check:Battery trickle

charge voltage,Battery charge

voltage level.

Check and record calibration of all

meters on the equipment.

6M 5. Rectifier. Switch on and check: Battery trickle

charge voltage, Battery charge

voltage level.

Check and record calibration of all

meters on the equipment.

6MOther

8. Inverter. Switch on and check the Inverter

Control Unit control voltage. When

operating correctly, check and

record the output voltage and

frequency.

Compare with voltages recorded on

test certificate.Record the results

and report any significant

differences. Check and record the

calibration of all meters.

6M 8. Inverter. Switch on and check the Inverter

Control Unit control voltage. When

operating correctly, check and

record the output voltage and

frequency.

Compare with voltages recorded on

test certificate. Record the results

and report any significant

differences. Check and record the

calibration of all meters.

6MOther

a) lead acid, Check condition. See POWER GENERATION

BATTERIES.

6M a) lead acid, Check condition. See Power generation batteries

SFG 43-03.

6MTechnical

b) other types. Check condition and report to client

if replacement is required.

Batteries should be disposed of only


Environmental Regulations

recommendations.

6M b) other types. Check condition and report to client

if replacement is required.

Batteries should be disposed of only


Environmental


shh/index.htm) Regulations

recommendations.

6MOther

Page 405 of 614

POWER SUPPLIES

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The section on Power Supplies covers all those aspects of providing power to the point of use and

includes switchgear, cables and outlets operating at 415 volts and below. Areas needing particular

attention are contacts, starters, phase loading, maximum demand control and power factor correction

equipment. The latter two are particularly relevant in terms of energy saving and controlling electricity

costs where a client is on a maximum demand tariff.

Unbalanced loading of phases often occurs where the site electricians make or alter connections to

plant and equipment using the nearest available power source. Unbalanced currents lead to

overheating of conductors, energy wastage and in extreme cases can be the cause of fires.

Dirty, pitted or worn contacts can lead to overheating of starters, equipment failure, and cause

interference on communications equipment. Lack of attention may result in fusing together of the

contacts which could prevent a shut down in an emergency.

Specialist advice and contractors should be sought for supplies above 415 Volts.

This section on Power Supplies covers all those aspects of providing power to the point of use and

includes switchgear, cables and outlets operating at 415 volts and below. Areas needing particular

attention are contacts, starters, phase loading, maximum demand control and power factor correction

equipment. The latter two are particularly relevant in terms of energy saving and controlling electricity

costs where a client is on a maximum demand tariff.

Unbalanced loading of phases often occurs where the site electricians make or alter connections to

plant and equipment using the nearest available power source. Unbalanced currents lead to

overheating of conductors, energy wastage and in extreme cases can be the cause of fires.

Dirty, pitted or worn contacts can lead to overheating of starters, equipment failure, and cause

interference on communications equipment. Lack of attention may result in fusing together of the

contacts which could prevent a shut down in an emergency.

Specialist advice and service providers should be sought for supplies above 415 Volts.

Check arc shields for the presence of asbestos containing material prior to dismantling any

equipment, if suspected STOP WORK. Take actions in accordance with the Asbestos Regulations.


Other

Page 407 of 614

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MAIN SWITCH PANEL AT SUPPLY INTAKE44-02 44-02 MAIN SWITCH PANEL AT SUPPLY INTAKE

The frequencies for the tasks given below are guideline only and shall be individually assessed per

site. Suitable isolation to be undertaken prior to commencement of work.

Added


1. General Carry out a visual inspection and

operational check. check for;

a) All contacts, fuse bridges, phase

barriers etc. for signs of

arcing/burning where accessible

without interrupting the supply.

b) Time clocks, timing relays etc.,

are at correct time/setting.

c) Where provided, all indicator

lamps are working, replace lamps

as required.

d) Check that all trunking, conduit

cable gland terminations are

secure, adjust accordingly.

e) Check all indicator gauges and

meters, check for cracked

glass/covers, replace as found.

f) Check correctness of labelling.

g) Check enclosures for holes and

damage.

Check arc shields for the presence

of asbestos containing material

prior to dismantling any equipment,

if suspected STOP WORK. Take




3MAdded

4. Panel Doors Check all door and cover gaskets.

Inspect door hinges and locks.

Lightly lubricate as found

necessary. Ensure all doors and

access panels can be securely

closed and locked.

12MAdded

11. Earth Bars Check all connections and bonding

to earth bars. Check earth bars and

insulators for security

12MAdded

13. Main

Connections

Check all connections using

infra-red equipment [thermal

imaging].

Must be on normal load24MAdded

1.Panel exterior. Check for physical or mechanical

damage. Touch up paintwork after

removing signs of corrosion.

12M 3.Panel exterior. Check for physical or mechanical



12MOther

2.Busbars. Check for visible signs of

overheating, loose connections etc.

12M 5.Busbars. Check for visible signs of


Check interior of busbar

compartments clean out dust and

dirt

12MTechnical



12M Deleted

3.Phase balance

and loading.

Check and report if phases are

unbalanced or overloaded.

Unbalanced phases and

overloading can lead to over-heating

of switchgear and cabling.

12M 6.Phase balance

and loading.

Check and report if phases are

unbalanced or overloaded.

Unbalanced phases and

overloading can lead to over-heating

of switchgear and cabling.

12MOther

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4.i)Main ACB. Check switching mechanism, Clean and lubricate as necessary.12M 7.i)Main ACB. Check switching mechanism, Clean and lubricate as necessary.

Check operation of incomer circuit

breakers, both manually and where

possible by simulating a fault via an

injection device

12MTechnical

4.ii) Main fuse

switch.

Check switching mechanism,12M 7.ii) Main fuse

switch.

Check switching mechanism,

Service, clean and lubricate

As per manufacturers

recommendations

12MTechnical

4.iii) Main MCCB. Check cable and busbar

connections.

Use torque spanner to panel

manufacturer's settings. Check

electrical impedance with approved

test instrument.

12M 7.iii) Main MCCB. Check cable and busbar

connections.

Use torque spanner to panel

manufacturer`s settings. Check

electrical impedance with approved

test instrument. Check operation of

incomer circuit breakers, both

manually and where possible by

simulating a fault via an injection

device

12MTechnical

4.iv) Main isolator. Check switching mechanism. Report any variation.12M 7.iv) Main isolator. Check switching mechanism.



recommendations. Report any

variation.

12MTechnical

5.Instrumentation For specialised maintenance of

instrumentation see CONTROL

PANELS.

8.Instrumentation For specialised maintenance of

instrumentation see Control panels

SFG 14.

12MOther

6. Insulated

phase barriers.

Ensure that they are in place and

free from contamination.

12M 9. Insulated

phase barriers.

Ensure that they are in place and

free from contamination.

12MOther

7. Cabling

terminations.

Check all neutral, earth and

auxiliary connections and

terminations.

12M 10. Cabling

terminations.

Check all neutral, earth and

auxiliary connections and

terminations.

12MOther

8. General. Check for presence of moisture.

Remove any build up of dirt or

other contaminants. Check that

appropriate labels and warning

notices are clean and in place.

Report to client if significant.12M 12. General. Check for presence of moisture.

Remove any build up of dirt or other

contaminants. Check that

appropriate labels and warning

notices are clean and in place.

Look for obvious signs of

malfunction, such as overheating,

unusual odours, discolouration and

noise

Report to the client if significant.12MTechnical

2. General -

Thermal imaging

Check using thermal imaging and

inspect for signs of hot spots and

overheating.

12MAdded

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POWER DISTRIBUTION UNIT (PDU)44-05 44-05 POWER DISTRIBUTION UNIT (PDU)

Caution: 1. Before commencing any maintenance work on PDUs read the notes in the Introduction

2. Work must only be carried out by Competent persons

3. All work must be subject to risk assessment and formal method statements

4. Prior to testing, ensure to isolate voltage sensitive equipment.

Caution: 1. Before commencing any maintenance work on PDUs read the notes in the Introduction

section SFG 44-01.

2. Work must only be carried out by Competent persons

3. All work must be subject to risk assessment and formal method statements

4. Prior to testing, ensure to isolate voltage sensitive equipment.



Other


2. General -

Thermal imaging



overheating.

12MAdded

2.Mains

isolator(Door

isolator)


interlock.

12M 3.Mains

isolator(Door

isolator)


interlock.

12MOther



12M 4.Busbars. Check for visible signs of


12MOther

4.Insulating

barriers.

Check that insulating barriers are in

place, particularly over incoming

terminals.

12M 5.Insulating

barriers.

Check that insulating barriers are in

place, particularly over incoming

terminals.

12MOther

5.Power

contactors.

Check contactor for correct

mechanical and electrical

operation.strip and clean interior.

Inspect and clean magnetic pole

faces. Check moving contacts for

wear or 'pitting'. Check coil for over-

heating or insulation breakdown.

Clean out arc chutes.

Damaged contacts should be

redressed or replaced as necessary.

Use approved contact lubricant as

recommended by manufacturer.

Use approved contact lubricant if


On re-assembly check all electrical

connections.

12M 6.Power

contactors.

Check contactor for correct

mechanical and electrical

operation. Strip and clean interior.

Inspect and clean magnetic pole

faces. Check moving contacts for

wear or `pitting`. Check coil for

overheating or insulation

breakdown. Clean out arc chutes.

Damaged contacts should be

redressed or replaced as necessary.

Use approved contact lubricant as

recommended by manufacturer.

Use approved contact lubricant if


On re-assembly check all electrical

connections.

12MOther

6.Starters, Frequency of maintenance will vary

depending on starting

duty/frequency of unit but in no

circumstances should it exceed

twelve months.

7.Starters, Frequency of maintenance will vary

depending on starting

duty/frequency of unit but in no

circumstances should it exceed

twelve months.

Other

-star delta,-two

speed-dual wound,

-two speed-pole

change,

-reversing, -auto

transformer.

See relevant sections. -star delta,-two

speed-dual

wound, -two

speed-pole

change,

-reversing, -auto

transformer.

See relevant sections in Starters

SFG 54.

12MTechnical

7.Thermal

overloads.

Inspect for signs of

overheating,Check electrical

connections for tightness and

security,

Replace if necessary after having

established the cause and rectify it.

12M 8.Thermal

overloads.

Inspect for signs of overheating,

Check electrical connections for

tightness and security,

Replace if necessary after having

established the cause and rectify it.

12MOther

Page 410 of 614

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8.Magnetic

overloads.

Inspect for signs of overheating.


tightness and security. Check oil

levels in dashpots, if cloudy or

sludge has formed, clean out

dashpot with solvent and refill.

Check 'time' delay mechanism.

Operate 'test' facility to ensure

switchgear de-energises in a clean

and positive operation. Inspect trip

settings.

Use only manufacturer's

recommended fresh oil. Select

correct dashpot drain hole if

necessary. Adjust if necessary to

give correct protection for connected

load.

12M 9.Magnetic

overloads.

Inspect for signs of overheating.


tightness and security. Check oil

levels in dashpots, if cloudy or

sludge has formed, clean out

dashpot with solvent and refill.

Check `time` delay mechanism.

Operate `test` facility to ensure

switchgear de-energises in a clean

and positive operation. Inspect trip

settings.

Use only manufacturer`s

recommended fresh oil. Select

correct dashpot drain hole if

necessary. Adjust if necessary to

give correct protection for connected

load.

12MOther

9.Panel wiring. Inspect for signs of overheating or

burn marks. Replace any suspect

conductors. Check all connections,

terminations, earth cables and links

for security and tightness. Ensure

cable connections are tight and

correctly terminated. Check that the

panel is correctly bonded to earth.

12M 10.Panel wiring. Inspect for signs of overheating or

burn marks. Replace any suspect

conductors. Check all connections,

terminations, earth cables and links

for security and tightness. Ensure

cable connections are tight and

correctly terminated. Check that the

panel is correctly bonded to earth.

12MOther

10.Fuses and/or

miniature circuit

breakers (MCB).

Check for damage. Check for

correct rating. Check tightness of

fuse link connections. Check free

operation of MCB mechanisms.

Check for evidence of overheating.

Ensure spare fuses are not 'blown',

replace with correct rating schedule,

if necessary. Renew where

necessary.

12M 11.Fuses and/or

miniature circuit

breakers (MCB).

Check for damage. Check for

correct rating. Check tightness of

fuse link connections. Check free

operation of MCB mechanisms.

Check for evidence of overheating.

Ensure spare fuses are not `blown`,

replace with correct rating schedule,

if necessary. Renew where

necessary.

12MOther

11.General. Check for presence of moisture.

Remove any build up of dust or any

other contamination.

Report to client if significant.12M 12.General. Check for presence of moisture.

Remove any build up of dust or any

other contamination.

Report to the client if significant.12MOther

12.Instrumentation

. a)

ammeters and

voltmeters,

b) selector

switches,

Check for accuracy and correct

operation. Check for operation. Test

for operation.

Compare with Certified test

instrument applied to same circuit.

Replace as necessary

12M 13.Instrumentation

. a)

ammeters and

voltmeters,

b) selector

switches,

Check for accuracy and correct

operation. Check for operation. Test

for operation.

Compare with Certified test

instrument applied to same circuit.

Replace as necessary

12MOther

Page 411 of 614

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EARTHING44-06 44-06 EARTHING

Danger can arise when removing a conductor connected to earth unless suitable precautions are

taken

Added


1.Earth electrodes. Check: Integrity of conductor.

Associated connections. Condition

of electrode and soil.

Test in Accordance with method in

BS7430:1991.

Record details and compare with

earlier records as any deterioration

may be gradual. Resistivity of

electrode may be affected by

corrosion, damage or soil condition.

See BS7671 the IEE wiring

regulations.

12M 1.Earth electrodes. Check: Integrity of conductor.

Associated connections. Condition

of electrode and soil.

Test in Accordance with method in

BS

(www.bsi-global.com)7430:1998.

Record details and compare with

earlier records as any deterioration

may be gradual. Resistivity of

electrode may be affected by

corrosion, damage or soil condition.

See BS7671 the IEE

(www.iee.org.uk) wiring regulations.

12MLegislative

2.Residual current

devices (RCD)(to

BS 4293)

Test using test button. Responsibility for this check should

be agreed with the client.

3M 2.Residual current

devices (RCD)

Test using test button. Responsibility for this check should


3MLegislative

Page 412 of 614

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DISTRIBUTION BOARDS44-07 44-07 DISTRIBUTION BOARDS

Note: It is essential to maintain the integrity of cabinets and panels against the ingress of dust and

vermin, the latter can cause severe damage to cables and thus create a fire hazard.

Confirm details of any pre agreed disruption to electrical supplies.

It is essential to maintain the integrity of enclosures against the ingress of dust and vermin, the latter

can cause severe damage to cables and thus create a fire hazard.

Technical


2.Cable insulation. Check condition and inspect for

signs of overheating.

If possible identify cause of

overheating and report.

12M 3.Cable insulation. Check condition and inspect for

signs of overheating.

If possible identify cause of

overheating and report.

12MOther

3. Fuse carriers

and MCBs

Check for damage,Check rating(s),

Check free operation of MCB

mechanisms,

Ensure fuses are not

'blown'.Replace with correct rating

as per schedule if necessary.

12M 4. Fuse carriers

and MCBs

Check for damage, Check rating(s),

Check free operation of MCB

mechanisms,

Ensure fuses are not `blown`. Any

fuses that are blown should be

replaced with correct rating as per

schedule

12MTechnical

4. Circuit charts. Check for accuracy of descriptions.

Ensure labels are securely fixed to

exterior of door.

12M 5. Circuit charts. Check for accuracy of descriptions.

Ensure labels are securely fixed to

exterior of door.

12MOther

5. Cable

terminations.

Check all phase, neutral and earth

connections and termination.

12M 6. Cable

terminations.

Check all phase, neutral and earth

connections and termination.

12MOther

6.Conduit and

cable gland

terminations.

Check for tightness.12M 7.Conduit and

cable gland

terminations.

Check for tightness.12MOther

7. RCDs. Check operation via test button. Responsibility for this check should


3M 8. RCDs. Check operation via test button. Responsibility for this check should


3MOther

2. General Locally isolate incoming electrical

supply. Open cover panels / access

doors. Check for signs of

overheating, unusual odours and

noises during operation. Remove

any build up of dirt and dust on

insulating components. Clean

equipment generally.

After all works [listed below]

completed securely refix cover

panels / access doors

12MAdded

Page 413 of 614

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RING MAIN and SUB CIRCUITS44-08 44-08 ELECTRICAL INSTALLATION - GENERALLY

Carry out all work and provide all services required to all areas specified. Routine inspection work

includes inspection of installations generally in accordance with 17th Edition of IEE Regulations. Refer

to requirements of BS7671:2008. Testing should be carried out in the following sequence to the

relevant items: Continuity of protective conductors, main and supplementary bonding. Continuity of

ring final circuits. Insulation resistance. Site applied insulation. Protection by separation of circuit.

Protection by barriers or enclosures provided during erection. Insulation of non conducting floor and

walls. Polarity. Earth electrode resistance. Earth fault loop impedance. Operation or residual current

devices (RCD). Electrical testing should be carried out by a competent qualified electrician fully versed

in the system installed. The incoming supply to distribution switch boards must be isolated by locking

off LV circuit breakers, fuse switches and supplies from other distribution switchboards as detailed on

record drawings, as determined on site by the provider and as instructed by the client before any work

commences.

Installation should be checked with suitable, reliable test equipment. Precautions must be taken to

ensure tripped circuit devices cannot be accidentally closed, by either padlocking in the `OFF` position

or withdrawing the device as applicable. Where incoming supplies have been isolated, certain

auxiliary / control supplies may be `LIVE` due to external sources, e. g. Battery units.

It is essential that results from installation testing are recorded and the records are maintained and

updated annually.

Any electrical systems found to deviate from regulatory recommendation should be identified and

appropriate repair action taken.

Frequency shown is a guideline, actual frequencies will vary according to the type of installation, type

and use of building and the findings of any previous inspection.

Added


1.Polarity and

continuity.

Check. Carry out checks in accordance with

IEE regulations.

12M 1. Small Power

Circuits/Outlets

Small Power Circuits/Outlets

Examine all small power outlets

within designated are, check for

damage and ensure any

disconnection switches operate

correctly, isolating electrical supply.

Check operation of RCD-protected

socket outlets by utilising Test

Button, reset RCD following Test.

12MAdded

2.Sockets. Test action and polarity of socket

outlets. Damaged socket outlets

must be replaced.

Ensure shutters are functioning

correctly.

12M Deleted

3.Earthing. Check arrangements and test. Carry out checks in accordance with

IEE regulations.

12M Deleted

4.Insulation

resistance.

Check.12M Deleted

Spur outlets Deleted

1.Condition. Check for physical damage.12M Deleted

Page 414 of 614

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Reason For

Change

2.Fuse rating. If fused, check rating.12M Deleted

Page 415 of 614

Previous

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Reason For

Change

44-10 ISOLATORS/STARTERS/FUSESWITCHES



Added


1. General Carry out a visual inspection and

operational check. check for;

a) All contacts, fuse bridges, phase

barriers etc. for signs of

arcing/burning where accessible

without interrupting the supply.

b) Check that all trunking, conduit

cable gland terminations are

secure, adjust accordingly.

c) Check correctness of labelling.

d) Check enclosures for holes and

damage.

e) Check enclosures and confirm IP

rating is suitable for location.

f) Check for correctness of labeling.

Check arc shields for the presence

of asbestos containing material

prior to dismantling any equipment,

if suspected STOP WORK. Take




3MAdded

2. General -

Thermal imaging



overheating.

12MAdded

3. Isolating

mechanism

Check switching mechanism.



recommendations. Report any

variation.

12MAdded

4. Fault handling Check equipment to confirm fault

handling capabilities

12MAdded

5. General -

internal

Check interior of device, clean out

dust and dirt

12MAdded

Page 416 of 614

PUMPS

Page 417 of 614

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Reason For

Change

PUMPS - General45-01 45-01 PUMPS - General


1. Noise,

vibration and

overheating.

Check, rectify if possible and

report.

6M 1. Noise,

vibration and

overheating.

Check, rectify if possible and report.

Check all holding down bolts,

tighten if required.

Check casing for physical or

mechanical damage. Touch up

paintwork after removing signs of

corrosion

6MTechnical

2. Lubrication. Lubricate bearings and motors.6M 2. Lubrication. Lubricate bearings and motors.

Where suitable lubrication points

are provided – do not lubricate

bearings and motors that are fitted

with ‘sealed for life’ varieties. Seek

advice from manufacturer if in

doubt.

Use only oil / grease that is in


recommendations

6MTechnical

3. Drives, pulleys,

AV mounts and

drive couplings.

Check and adjust where necessary.6M 3. Drives,

pulleys, belts, AV

mounts and drive

couplings.

On belt driven pumps - Inspect and

adjust as required. Replace belts if

condition warrants it. Ensure motor

and drive and pulley are correctly

aligned

6MTechnical

7. Electrical

connections.

Check.12M 7. Electrical Check motor electrical terminals

and tighten as required.

Check electrical connections.

Check and record full load running

current and compare with

nameplate details .

Check function & operation of local

isolation device (stoplock/isolator).




check for


cables/conduits.



12MTechnical

8. Motor vent

slots.

Clear. Under certain conditions e.g. a dusty

environment, more frequent

cleaning may be required. (See also

MOTORS)

12M 8. Motor vent

slots.

Clear. Under certain conditions e.g. a

dusty environment, more frequent

cleaning may be required.See also

Motors SFG 39.

12MOther

9. Drive guards. Check and rectify security.12M 9. Drive guards. Check they are in place and

secure.

12MTechnical

10. Valves

Isolation,

regulation and

non-return valves

Check operation. Tighten glands or

repack if necessary

See Valves SFG61.12MAdded

11. Drain and

tundish (where

fitted)

Check for blockage, clean12MAdded

Page 418 of 614

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Reason For

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12. Pump

Pressures

Check and Record12MAdded

Page 419 of 614

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CIRCULATING PUMPS-general45-02 45-02 CIRCULATING PUMPS-general


13. Drive guards.

(where fitted

Check they are in place and secure3MAdded

1. Casings. Inspect and clean as required.3M 1. Noise,

vibration and

overheating.







corrosion

3MTechnical

2. Bearings and

glands.

Inspect for wear, lubricate bearings

and motors, repack glands as

required.

Report if defective.3M 2. Bearings and

glands.



required. Where suitable lubrication

points are provided – do not

lubricate bearings and motors that

are fitted with ‘sealed for life’

varieties. Seek advice from

manufacturer if in doubt



recommendations

Report if defective.

3MTechnical

7. Motor electrical

terminals.

Inspect and tighten as required. (See also MOTORS.)3M 7. Electrical. Check function & operation of local

isolation device (stoplock/isolator).




check for


cables/conduits.



Take and log motor current and

compare with nameplate details .

See also Motors SFG 39.3MTechnical

9. Pulley(s). Check and realign if necessary.3M 9. Pulley(s) if

Fitted.

Check and realign if necessary.3MTechnical

10. Isolation,

regulation and

non-return valves.


repack if necessary.

3M 10. Valves

Isolation,

regulation and

non-return valves



See Valves SFG61.3MTechnical

12. Anti-vibration

mounts.

Check and clean. Generally report any defects to

client.

3M 12. Anti-vibration

mounts.

Check and clean. Generally report any defects to the

client.

3MOther

Page 420 of 614

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Reason For

Change

CENTRIFUGAL PUMPS45-03 45-03 CENTRIFUGAL PUMPS


1. Casing. Inspect for external condition and

signs of leaks.

3M 1. Casing general

- Noise, vibration

and overheating

Inspect for external condition and

signs of leaks. Check casing for

physical or mechanical damage.

Touch up paintwork after removing

signs of corrosion.



Check, rectify if possible and report

3MTechnical

2. Glands and

mechanical seals.


rate.

If there are signs of leaks, tighten

nuts or repack gland. Caution - do

not over tighten.

3M 4. Glands and

mechanical seals.


rate.

If there are signs of leaks, tighten

nuts or repack gland. Caution - do

not over tighten.

3MOther

3.Valves, cocks

and drains.

Check externally for leaks. Rotate spindles and handwheels to

check freedom of operation,

examine drains for signs of gland

leakage.

3M 5.Valves, cocks

and drains.

Check externally for leaks. Rotate spindles and handwheels to



leakage. See Valves SFG61.

3MOther

4. Strainers and

exhausters.

Check external condition and

freedom of flow.

Check self priming action where

fitted.

3M 6. Strainers and

exhausters.

Check external condition and

freedom of flow.

Check self priming action where

fitted.

3MOther

5. Belt drives. Check for condition and alignment. Correct tensioning where necessary.3M 7. Belt drives. Check for condition and alignment.

Replace belts if condition warrants

it.

Correct tensioning where necessary.3MTechnical

6. Couplings,

pulleys, guards

and holding down

bolts.

Inspect and rectify any faults.3M 8. Couplings,

pulleys, guards

and holding down

bolts.

Inspect and rectify any faults.3MOther

7. Isolation of

pump from

electrical and

mechanical power.

Remove circuit supply fuses. For safety reasons pump should be

isolated before commencing work.

3M 2. Isolation of

pump from

electrical and

mechanical power.

Remove circuit supply fuses. For safety reasons pump should be

isolated before commencing work.

3MOther

8. Pump. Drain down and where applicable,

strip, test and adjust parts listed in

'notes' column. Lubricate and

grease.

Parts to be tested and adjusted

include: glands and packing, gland

compression springs, lantern rings,

seals, throwers, couplings, rubber

sleeves and pins, nuts and spring

washers.

3M 9. Pump. Drain down and where applicable,

strip, test and adjust parts listed in

`notes` column. Lubricate and

grease.

Parts to be tested and adjusted

include: glands and packing, gland

compression springs, lantern rings,

seals, throwers, couplings, rubber

sleeves and pins, nuts and spring

washers.

3MOther

9. Reassembly. Test functionally.3M 10. Reassembly. Test functionally.3MOther

3. Electrical Examine and report condition of all



check for


cables/conduits.




compare with nameplate details

3MAdded

Page 421 of 614

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Reason For

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11. Drain and

tundish (where

fitted)

Check for blockage, clean3MAdded

12. Pump

Pressures

Check and Record3MAdded

Page 422 of 614

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PRESSURISATION PUMPS45-04 45-04 PRESSURISATION PUMPS


7. Valves

Isolation,

regulation and

non-return valves

Check externally for leaks Rotate spindles and handwheels to



leakage.

See Valves SFG61.

3MAdded

8. Electrical Examine and report condition of all



check for


cables/conduits.





3MAdded

13. Pump

Pressures

Check and record3MAdded

1. Pump base

and connections.

Ensure pump base is level and

pipework not strained.

Check that anti-vibration mountings

are satisfactory and vibration is not

being transferred to the pipework.


- Noise, vibration

and overheating.


pipework not strained. Check

casing for physical or mechanical








being transferred to the pipework.

3MTechnical

2. Strainer

elements.

Clean.3M 2. Strainer

elements.

Inspect and clean as required3MTechnical

4. Motors and

bearings.





overhauled annually, see MOTORS.

3M 4. Motors and

bearings.





overhauled annually. See also

Motors SFG 39.

3MOther

7. Control and

safety switches.

Inspect and check. These include low water level

cut-out switches, high and low

pressure sensing switches,

electrodes, connector caps and

contacts. Report any defects to

client.

3M 9. Control and

safety switches.





contacts. Report any defects to the

client.

3MOther

8. Control,

pressure relief and

reducing valves,

air vents, purgers

and constant flow

regulators

Test for correct operation and

rectify any faults.

Report any defects to client.3M 10. Control,

pressure relief and

reducing valves,

air vents, purgers

and constant flow

regulators


rectify any faults.

Report any defects to the client.3MOther

9. Diaphragm

expansion tanks.

Inspect. Ensure diaphragms are sound and

air cushion pressure is correct.

3M 11. Diaphragm

expansion tanks.

Inspect. Inspect where possible Ensure diaphragms are sound and

air cushion pressure is correct.

3MTechnical

Page 423 of 614

Previous

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Reason For

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10.Test run

pressure booster

sets, pressurising

units, and filling

pump.




controls and change-over switches.

3M 12.Test run

pressure booster

sets, pressurising

units, and filling

pump.





3MOther

Page 424 of 614

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Reason For

Change

ROTARY HAND PUMPS45-05 45-05 ROTARY HAND PUMPS


1. Fixings and

hoses.

Check security and leak tightness.

Remedy any faults.

12M 1. Casing, fixings

and hoses

Check security and leak tightness.

Remedy any faults. Check casing

for physical or mechanical damage.

Touch up paintwork after removing

signs of corrosion.

12MTechnical

Page 425 of 614

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SECONDARY HOT WATER CIRCULATING PUMPS45-06 45-06 SECONDARY HOT WATER CIRCULATING PUMPS


1. Casing. Inspect and clean as required.6M 1. Casing general

- Noise, vibration

and overheating

Inspect and clean as required.




corrosion.


6MTechnical

2. Bearings,

glands and seals.



required.

Report if defective.6M 2. Bearings,

glands and seals.



required. Where suitable lubrication

points are provided – do not

lubricate bearings and motors that

are fitted with ‘sealed for life’

varieties. Seek advice from

manufacturer if in doubt.



recommendations. Report if

defective.

6MTechnical

3. Bolts, pulleys,

couplings and

belts (where

fitted).

Inspect and adjust as required.


it.


are correctly aligned. (See also

MOTORS

6M 3. Bolts, pulleys,

couplings and

belts (where

fitted).

Inspect and adjust as required.


it.


are correctly aligned. See also

Motors SFG 39.

6MOther

6. Isolation,

regulation and

non-return valves.



6M 6. Isolation,

regulation and

non-return valves.



See Valves SFG61.6MOther

8. Anti-vibration

mounts.

Check and clean. Generally report any defects to

client.

12M 8. Anti-vibration

mounts.

Check and clean. Generally report any defects to the

client.

12MOther

10. Full load

running current.

Check and record.12M 10. Electrical Examine and report condition of all



check for


cables/conduits.





12MTechnical

Page 426 of 614

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SEWAGE OR DRAINAGE PUMPS SUBMERSIBLE45-07 45-07 SEWAGE OR DRAINAGE PUMPS SUBMERSIBLE


1. Pump motor/s. Check insulation value of motor

windings.

For detailed maintenance schedule

see MOTORS. Advise client if

further investigation is required.

6M 2. Pump motor/s. Check insulation value of motor

windings.


see also Motors SFG 39. Advise the

client if further investigation is

required

6MTechnical

2. Pump/s. Check pumping performance of all

pumps. Withdraw pump from pit,

check impeller for wear and

blockages. Check seal chamber oil.

Visual observation of changing

levels satisfactory. Clean and report

as necessary. Renew if necessary.

6M 3. Pump/s. Check pumping performance of all

pumps. Check impeller for wear

and blockages. Check seal

chamber oil. Drain sample of oil

from pump and check for moisture,

replenish/replace as required.

Check pump mountings



as necessary. Renew if necessary.

6MTechnical

3. Valves. Check satisfactory operation of all

isolating and non-return valves.

See relevant section for more

detailed information on the

maintenance of valves.

6M 5. Valves. Check satisfactory operation of all




maintenance of valves. See SFG61

VALVES

6MOther

4. Controls

(operational).

Inspect and check. Report any defects to client.6M 6. Controls

(operational).

Inspect and check. Check operation

of float/level switch controls

Report any defects to the client.6MTechnical

5. Building

management

system controls.

Simulate every function to ensure


Reset after test, ensure that alarm

and operational information is

transmitted to delegated terminal.

For more detailed information about

the maintenance of BMS see

relevant section.

6M 7. Building

management

system controls.







the maintenance see relevant

section BMS SFG 6.

6MOther

1. Casing general

- Noise, vibration

and overheating

Isolate pump(s) and withdraw form

sump. Visually inspect pump for


Check pump intake is clear and

unobstructed. Clean pump casing

as required. Touch up paintwork

after removing signs of corrosion.


6MAdded

Page 427 of 614

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Reason For

Change

4. Electrical Remove motor terminal covers,

check connections for tightness and

terminal block for damage or

dampness. Open starter and check

condition of wiring and contacts,

clean and blow out. Ensure that

overload devices are operational

and set for correct loading. Carry

out the following tests to all pumps

and record results:-a. Insulation

resistance test on wiring and

motors. b. Earth loop impedance

test on case or frame of units. c.

Load test on motors (start and run

current). Compare results with

manufacturers specification.

Check that power leads at motors

are undamaged and are securely

held.

6MAdded

8. Return pump to

service

Check sump is free of debris, clean

as required.

Replace pump(s) and check

operation before closing sump

6MAdded

Page 428 of 614

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Reason For

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SEWAGE and DRAINAGE PUMPS: DRYWELL45-08 45-08 SEWAGE and DRAINAGE PUMPS: DRYWELL


3. Casing general

- Noise, vibration

and overheating









6MAdded

1. Drywell. Check for seepage, if necessary

pump out.

Report any excessive seepage to

client.

6M 1. Drywell. Check for seepage, if necessary

pump out.

Report any excessive seepage to

the client.

6MOther

2. Drywell high

level alarm.

Check for correct operation. If defective, report to client as soon

as possible.

6M 2. Drywell high

level alarm.

Check for correct operation. If defective, report to the client as

soon as possible.

6MOther

3. Valves. Check for satisfactory operation of

all isolating and non-return valves.



maintenance of valves.

6M 4. Valves. Check for satisfactory operation of



detailed information on Valves

SFG61.

6MOther

4. Pump(s). Carry out maintenance. See PUMPS- GENERAL.6M 5. Pump(s). Check pumping performance of all






See Pumps - general SFG456MTechnical

5. Pump

motor(s).

Check insulation value of motor

windings.


see - MOTORS. Advise client if

further investigation is required.

6M 6. Electrical and

Pump motor(s).

Check pump mountings. Remove

motor terminal covers, check










resistance test

on wiring and motors. b. Earth loop

impedance test on case or frame of

units. c. Load test on motors (start

and run current). Compare results

with manufacturers specification.



held.


see Motors SFG 39. Advise the


required

6MTechnical

6. Level or

pressure controls.

Check settings and test

functionally.

Report any defects to client.6M 7. Level or

pressure controls.


functionally.


Page 429 of 614

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Reason For

Change

7. Building

management

system controls.







the maintenance of BMS , see

relevant section.

6M 8. Building

management

system controls.








section BMS SFG 6.

6MOther

Page 430 of 614

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Reason For

Change

SEWAGE PUMPS: COMPRESSED AIR45-09 45-09 SEWAGE PUMPS: COMPRESSED AIR


1. Air

compressors.

Carry out maintenance, if

necessary pump out.


see PIPEWORK SYSTEMS.

6M 1. Air

compressors.

Carry out maintenance, if

necessary pump out.


see Pipework systems SFG 40-08

6MTechnical

2. Air receivers. Carry out inspection and

maintenance.



Regulations 1989 apply.

6M 2. Air receivers. Carry out inspection and

maintenance.

The Pressure Systems Safety

Regulations 2000 apply.

6MTechnical

3. Valves. Check for satisfactory operation of


See VALVES for more detailed

information about the maintenance

of valves.

6M 3. Valves. Check for satisfactory operation of




SFG61.

6MTechnical

6. Controls

(operational).


functionally.

Report any defects to client.6M 6. Controls

(operational).


functionally.


Page 431 of 614

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Change

SUMP PUMPS: EXTENDED SHAFT45-10 45-10 SUMP PUMPS: EXTENDED SHAFT


1. Motor. Check insulation value of windings,

clean ventilation slots and lubricate.

For detailed maintenance schedule,

see MOTORS.

12M 2. Electrical and

Pump motor(s)

Remove motor terminal covers,

check connections for tightness and














manufacturers specification. Check

that power leads at motors are

undamaged and are securely held.

Check insulation value of windings,

clean ventilation slots and lubricate.


see also Motors SFG 39. Advise the


required

12MTechnical

2. Grease points

for extension

shaft.

Lubricate all bearings. Note and report any excessive

bearing noise.

3M 3. Grease points

for extension

shaft.

Check, rectify if possible and report Note and report any excessive

bearing noise.

3MOther

3. Pump/s. Check pumping performance of all

pumps. Withdraw pump from pit,

check impeller for wear and

blockages.



condition as necessary.

3M 4. Pump/s. Check pumping performance of all






Check pump mountings



condition as necessary.

3MTechnical

4. Valves. Check satisfactory operation of all


6M 5. Valves. Check satisfactory operation of all




SFG61.

6MTechnical

5. Controls

(operational).

Inspect and check. Report any defects to client.6M 6. Controls

(operational).

Inspect and check. Check operation

of float/level switch controls

Report any defects to the client.6MTechnical

6. Building

management

system controls.







maintenance see BMS Section.

6M 8. Building

management

system controls.








section BMS SFG 6.

6MOther

Page 432 of 614

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Reason For

Change

1. Casing general

- Noise, vibration

and overheating









12MAdded

7. Return pump to

service

Check sump is free of debris, clean

as required.

Replace pump(s) and check

operation before closing sump

6MAdded

Page 433 of 614

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Reason For

Change

WATER PUMPING PRESSURE BOOSTING SETS45-12 45-12 WATER PUMPING PRESSURE BOOSTING SETS


5. Electrical Check condition of local isolator,

open and clean if required. Remove



















held

12MAdded

12. Valves Check operation. Tighten glands or




SFG61.

3MAdded

1. Pump base

and connections.


pipework not strained.



being transferred to pipework.


- Noise, vibration

and overheating.


pipework not strained. Check

casing for physical or mechanical








being transferred to pipework.

3MTechnical

2. Strainer

elements.

Clean.3M 2. Strainer

elements.

Inspect and clean as required3MTechnical

4. Motors and

bearings.



Use recommenced grade of


overhauled annually, see MOTOR.

3M 4. Motors and

bearings.



Use recommenced grade of


overhauled annually. See also

Motors SFG 39.

3MOther

5. Drain holes,

pipes and tank.

Clean and ensure that all

blockages are cleaned.

3M 6. Drain holes,

pipes and tank.

Clean and ensure that all blockages

are cleaned. Check water level in

break tank.

3MTechnical

6. Guards and

shields

Check for security and safety. Adjust if necessary.3M 7. Guards and

shields

Check for security and safety. Adjust if necessary.3MOther

7. Control and

safety switches.





contacts. Report any defects to

client .

3M 8. Control and

safety switches.





contacts. Report any defects to the

client.

3MOther

Page 434 of 614

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Reason For

Change

8. Control,

pressure relief and

reducing valves &

constant flow

regulators.


rectify any faults.

Report any defects to client .3M 9. Control,

pressure relief and

reducing valves &

constant flow

regulators.


rectify any faults.


9. Hydraulic

accumulator (if

fitted).

Inspect and check gas cushion

pressure and adjust as necessary.

Ensure diaphragms are sound. Use

oxygen free nitrogen for topping up

pressure as necessary.

3M 10. Hydraulic

accumulator (if

fitted).

Inspect and check gas cushion

pressure and adjust as necessary.

Ensure diaphragms are sound. Use

oxygen free nitrogen for topping up

pressure as necessary. Ensure any

discharge can not endanger others.

3MOther

10.Test pressure

booster sets.

Run and carry out adjustments to

ensure satisfactory operation.



3M 11.Test pressure

booster sets.

Run and carry out adjustments to

ensure satisfactory operation.



Ensure any discharge of Oxygen

free Nitrogen can not endanger

others.

3MTechnical

11. Building

management

system controls.






See BMS.

3M 13. Building

management

system controls.






See Building management systems

SFG 06.

3MOther

Page 435 of 614

Previous

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Reason For

Change

45-13 OGDEN STEAM PUMP


WORK, close off the area. Take actions in accordance with the asbestos regulations.


Added


1. Operation check Carry out operation check in


instructions.

12MAdded

2. Vent and drain

lines

Ensure all drain lines and vent

pipes are clear.

12MAdded

3. Pump Strip, clean and overhaul pump,

check inlet, outlet and exhaust

valves and seats. Inspect float and

fulcrum pin assembly, check for

wear/damage, renew as required.

Refer to manufacturer`s hand book

before stripping down unit.

12MAdded

4. Steam traps

and pipework.

Examine interconnecting pipework

and steam trap/strainer assemblies,

check for correct operation,

clean/replace

strainer baskets as required.

12MAdded

Page 436 of 614

REFRIGERANT DISTRIBUTION SYSTEM

Page 437 of 614

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Reason For

Change

REFRIGERANT DISTRIBUTION SYSTEM46-01 46-01 REFRIGERANT DISTRIBUTION SYSTEM





Check for leaks should be part of the routine servicing. “Checked for leakage” means that the Joints,

valves including stems, seals, including seals on replaceable driers and filters, parts of the system

subject to vibration, connections to safety or operational devices of the equipment or system is

examined for leakage using direct or indirect measuring methods, focusing on those parts of the

equipment or system most likely to leak. The frequency of testing depends on refrigerant charge and

system type.

Systems containing: <3 kg no leak test required, 3 kg to 30 kg annual leak test required, 30 kg to 300

kg half yearly leak test required and >300 kg quarterly leak test required.

Hermetically sealed systems: <6 kg no leak test required, 6 kg to 30 kg annual leak test required, 30

kg to 300 kg half yearly leak test required and >300 kg quarterly leak test required.

These applications must also be checked for leakage within one month after a leak has been repaired

to ensure that the repair has been effective.

Plants with more than 300 kg must be fitted with a leakage detection system, which is defined as: “a

calibrated mechanical, electrical or electronic device for detecting leakage of refrigerants which, on

detection, alerts the operator”. The detection system must be checked at least once a year to ensure

proper functioning in line with manufacturers’ recommendations.

For any plant fitted with a leakage detection system (including those below the mandatory 300 kg

threshold), the frequency of leak checking can be halved, although an annual check remains the

minimum frequency.


Added




attendants.






Added

A) Normal

systems:

<3 kg

Check for refrigerant leaks. Any

leak of refrigerant should be dealt

with immediately.

0MAdded

B) 3 kg to 30 kg Check for refrigerant leaks. Any


with immediately.

12MAdded

C) 30 kg to 300 kg Check for refrigerant leaks. Any


with immediately.

6MAdded

Page 438 of 614

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Reason For

Change

D) >300 kg Check for refrigerant leaks. Any


with immediately.

3MAdded

E) Hermetically

sealed systems:

<6 kg



with immediately.

0MAdded

F) 6 kg to 30 kg Check for refrigerant leaks. Any


with immediately.

12MAdded

G) 30 kg to 300 kg Check for refrigerant leaks. Any


with immediately.

6MAdded

H) >300 kg Check for refrigerant leaks. Any


with immediately.

3MAdded

1. Sight

glass(es).

Check operation and cleanliness.

Test for refrigerant leaks.

Sight glasses, which should be fitted

on any system, indicate refrigerant

level and the presence of moisture.

Faults which may be observed are:-

a) bubbles in sight glass indicating a

shortage of refrigerant or a

restriction in the liquid line, b) a

change in the colour of the moisture

monitor from green to yellow

indicates the presence of moisture

in the system.

3M 2. Sight

glass(es).

Check operation and cleanliness.

Test for refrigerant leaks.

Sight glasses, which should be fitted

on any system, indicate refrigerant

level and the presence of moisture.

Faults which may be observed are:-

a) bubbles in sight glass indicating a

shortage of refrigerant or a

restriction in the liquid line, b) a

change in the colour of the moisture

monitor from green to yellow

indicates the presence of moisture

in the system.

3MOther

2. Superheat

setting of

thermostatic

expansion valve

(TEV)

Check operation following the

sequence outlined in the 'notes'

column. To adjust, remove valve

cap at base of valve, turn adjusting

stem counter clockwise to lower the

superheat or clockwise to increase

the superheat. CAUTION: Only

make one turn of the stem at a

time.

a) measure temperature of the

suction line at the point where the

TEV bulb is clamped. b) read gauge

pressure at compressor suction

valve, c) add estimated pressure

drop between bulb location and

suction valve. d) convert the sum of

the pressures to the equivalent

temperature and subtract this from

the actual suction line temperature.

This difference is the superheat.

Note:- It can take thirty minutes for a

new balance to be achieved. Record

new setting, it should be between 8

and 10ºC.

3M 3. Superheat

setting of

thermostatic

expansion valve

(TEV)

Check operation following the

sequence outlined in the `notes`

column. To adjust, remove valve

cap at base of valve, turn adjusting

stem counter clockwise to lower the

superheat or clockwise to increase

the superheat. CAUTION: Only

make one turn of the stem at a

time.

a) measure temperature of the

suction line at the point where the

TEV bulb is clamped. b) read gauge

pressure at compressor suction

valve, c) add estimated pressure

drop between bulb location and

suction valve. d) convert the sum of

the pressures to the equivalent

temperature and subtract this from

the actual suction line temperature.

This difference is the superheat. It

can take thirty minutes for a new

balance to be achieved. Record new

setting, it should be between 8 &

10oC.

3MOther

3. Oil separators. Inspect:- External condition of shell.

Leak tightness of connections.

Operation of valves and drains.

Operation of float valves.

Many small units are sealed and the

sight glass is on the oil separator.

12M 4. Oil separators. Inspect:- External condition of shell.

Leak tightness of connections.

Operation of valves and drains.

Operation of float valves.

Many small units are sealed and the

sight glass is on the oil separator.

12MOther

4. Glycol

concentration.

Check, if low, restore to

recommended concentration.

A fall in concentration may be the

result of leakage and pipework

should be checked.

3M 5. Glycol

concentration.



A fall in concentration may be the

result of leakage and pipework

should be checked.

3MOther

4. Glycol

concentration.



3M 6. Glycol

concentration.



3MOther

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5. High and low

pressure switches.

Check on operation of pressure

switch contacts and re-adjust to

correct operating pressures as

necessary. On completion of tests -

disconnect air pressure or vacuum

equipment and alarm test set -

remake electrical supply and alarm

cables - test functionally - return to

service.

Apply correct pressure or vacuum

reading to coincide with pressure

switch operating limits, note

pressure or vacuum reading at

which pressure switch contacts

make on both upper and lower

limits. Pressure switch isolation

valves to be opened, where fitted.

12M 7. High and low

pressure switches.

Check on operation of pressure

switch contacts and re-adjust to

correct operating pressures as

necessary. On completion of tests -

disconnect air pressure or vacuum

equipment and alarm test set -

remake electrical supply and alarm

cables - test functionally - return to

service.

Apply correct pressure or vacuum

reading to coincide with pressure

switch operating limits, note

pressure or vacuum reading at

which pressure switch contacts

make on both upper and lower

limits. Pressure switch isolation

valves to be opened, where fitted.

12MOther

6. Insulation. Check:- External condition.

Soundness of vapour barrier and/or

waterproof finish. Condition of

flange and valve boxes including

internal linings and fasteners.

It cannot be stressed too heavily

that ingress of water vapour has

to be minimised otherwise efficiency

will be reduced and energy wasted.

Pay particular attention to seals

round hangers and supports. Look

for damage due to leaks. Check

paintwork and identification bands.

3M 8. Insulation. Check external condition.

Soundness of vapour barrier and/or

waterproof finish. Condition of

flange and valve boxes including

internal linings and fasteners.

It cannot be stressed too heavily

that ingress of water vapour has to

be minimised otherwise efficiency

will be reduced and energy wasted.

Pay particular attention to seals

round hangers and supports. Look

for damage due to leaks. Check

paintwork and identification bands.

3MOther

Page 440 of 614

ROOM AIR CONDITIONERS

Page 441 of 614

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ROOM AIR CONDITIONERS unitary rev. cycle heat pump terminal units with

elec. htg. and rev. valve

47-01 47-01 ROOM AIR CONDITIONERS

Note: If unit is ceiling mounted cover office equipment immediately below any area of work . Room air conditioners [unitary reverse cycle heat pump terminal units with electrical heating and

reversing valve]










system type.













minimum frequency.

Technical




accordance with HSAWA

requirements.

6M 1. Status. Isolate electrically. Note: Isolation of electrical


accordance with HSAWA


6MOther

2.

Heating/cooling

coil.

Remove air entry filter, inspect coil

for dirt and clean as required.

Remainder of unit should be

cleaned annually.

6M 2.

Heating/cooling

coil.

Remove air entry filter, inspect coil

for dirt and clean as required.

Comb any area of fins that are

damaged

Remainder of unit should be

cleaned annually.

6MTechnical

7. Refrigeration

circuit.

Check for leaks. Indicated by oil smears at joints.6M 7. Refrigeration

circuit.

Check for leaks. For more details

on checking for leaks see above

Indicated by oil smears at joints.6MTechnical

10. Controls. Return to standard settings.6M 10. Controls. Return to standard settings. Check

date and times.

On any hand held controllers check

battery and replace as required. All

batteries should be disposed of only


Environmental requirements.

6MTechnical

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the routine servicing.






Added

A) Normal

systems:

<3 kg



with immediately.

0MAdded

B) 3 kg to 30 kg Check for refrigerant leaks. Any


with immediately.

12MAdded

C) 30 kg to 300 kg Check for refrigerant leaks. Any


with immediately.

6MAdded

D) >300 kg Check for refrigerant leaks. Any


with immediately.

3MAdded

E) Hermetically

sealed systems:

<6 kg



with immediately.

0MAdded

F) 6 kg to 30 kg Check for refrigerant leaks. Any


with immediately.

12MAdded

G) 30 kg to 300 kg Check for refrigerant leaks. Any


with immediately.

6MAdded

H) >300 kg Check for refrigerant leaks. Any


with immediately.

3MAdded

Page 443 of 614

SANITARY AND WASTE WATER PLUMBING

Page 444 of 614

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This section covers all aspects of the disposal of waste water and it is essential that both contractor

and client ensure that all actions and practices conform with the Health and Safety at Work Act

(HASAWA) and Environmental regulations. Certain activities may be covered by more than one

specialist function and in these areas it is essential that the responsibilities for particular tasks are

identified and allocated.

Note HSE Documents - INDG197 and 198.

Weil's Disease (Leptospirosis)

This reportable disease is carried by rats and can be passed on to humans hence strict

precautions must be taken to prevent infection. Attention is drawn to the need to carry out a risk

assessment and produce a method statement for operators and maintenance personnel to use. PPE

may be necessary.

Dangerous Gases

Special care is needed when entering pits and other below ground chambers to ensure that they are

properly ventilated and free from harmful gases.

Under Food Hygiene Regulations it is essential that operatives and maintenance personnel do

not work on clean water systems if they have been in contact with waste water or sewage.

Hospitals and similar facilities may call for specialist services, which should be identified and agreed

with the client.

Staff training must be up to date.

This section covers all aspects of the disposal of waste water and it is essential that both service

provider and client ensure that all actions and practices conform with the Health and Safety at Work

Act (HASAWA (www.hse.gov.uk)) and Environmental regulations. Certain activities may be covered by

more than one specialist function and in these areas it is essential that the responsibilities for

particular tasks are identified and allocated.

HSE Documents - INDG197 and 198.

Weil`s Disease (Leptospirosis)

This reportable disease is carried by rats and can be passed on to humans hence strict precautions

must be taken to prevent infection. Attention is drawn to the need to carry out a risk assessment and

produce a method statement for operators and maintenance personnel to use.

Dangerous Gases

Special care is needed when entering pits and other below ground chambers to ensure that they are

properly ventilated and free from harmful gases.

Under Food Hygiene Regulations it is essential that operatives and maintenance personnel do not

work on clean water systems if they have been in contact with waste water or sewage.

Hospitals and similar facilities may call for specialist services, which should be identified and agreed

with the client.

Staff training must be up to date.

Other

Page 445 of 614

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MACERATORS48-02 48-02 MACERATORS


1. Condition. Check: Condition of body and

attrition blades. Bearings. For

blockage and clear. Operation.

If there is evidence of severe wear

on the attrition blades, advise client

of need for replacement. If there has

been abuse or signs of jamming, by

for instance foreign objects, bearing

wear or distortion may be evident.

12M 1. Condition. Check: Condition of body and

attrition blades. Bearings. For

blockage and clear. Operation.

If there is evidence of severe wear

on the attrition blades, advise the

client of need for replacement. If

there has been abuse or signs of

jamming, by for instance foreign

objects, bearing wear or distortion

may be evident.

12MOther

2. Electrical

connections.

Check for tightness.12M 2. Electrical Examine and report condition of all




any flexible cables /conduits. 2.

Check for adequate earth

conductor and bonding is secure. 3.


local electrical isolation device. 4.

Carry out Earth

Continuity/Insulation Resistance

Tests

12MTechnical

Page 446 of 614

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INTERCEPTORS - Petrol and Oil48-03 48-03 INTERCEPTORS - Petrol and Oil

Note: Petrol filling stations are outside the scope of this specification. Where entry into confined

spaces is necessary, compliance with HSE Guidance note L101 Safe work in confined spaces 1997

and INDG 258 Work in confined spaces - is required. Staff training must be up to date.

Petrol filling stations are outside the scope of this specification.Where entry into confined spaces is

necessary, compliance with (www.hse.gov.uk) Guidance note L101 Safe work in confined spaces

1997 Approved code of practice, regulations and guidance 2nd edition (2009) and INDG 258 Work in

confined spaces - is required. Staff training must be up to date.

Legislative


Petrol interceptors.

1. Condition of

tankage.

Check and report any significant

deterioration.

Take care not to inhale any fumes.12M 1. Condition of

tankage.

Check and report any significant

deterioration.

12MOther

2. Water. Clean surface and remove any

floating solids. Any surface

contamination by oily substances to

be removed by vacuum separately

from sedimentary solids.

Any liquid or solids removed during

the cleaning process must be

disposed of in accordance with H &

S and Environmental and water

byelaw regulations.

12M 2. Water. Clean surface and remove any

floating solids. Any surface

contamination by oily substances to

be removed by vacuum separately

from sedimentary solids.

Any liquid or solids removed during

the cleaning process must be

disposed of in accordance with H &

S



and water byelaw regulations.

12MOther

Petrol interceptors.Added

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INTERCEPTORS - blowdown and sumps48-04 48-04 INTERCEPTORS - blowdown and sumps

Note: This subject comes within the scope of the HSE Guidance Notes PM60, L101 and PM5. Great

care must be taken when entering brick or concrete drainage pits because of the possible presence of

harmful gases. They must be vented to ensure the chamber cannot be pressurised over 0.1 bar g.

(1.5 psig). Where entry into confined spaces is necessary, compliance with HSE Guidance note L101

Safe Work in confined spaces 1997 and INDG 258 Work in confined spaces - is required. Staff

training must be up to date.

This subject comes within the scope of the HSE Guidance Notes PM60, L101 and PM5. Great care

must be taken when entering brick or concrete drainage pits because of the possible presence of

harmful gases. They must be vented to ensure the chamber cannot be pressurised over 0.1 bar g.

(1.5 psig). Where entry into confined spaces is necessary, compliance with (www.hse.gov.uk)

Guidance note L101 Safe Work in confined spaces 1997 Approved code of practice, regulations and

guidance 2nd edition (2009) and INDG 258 Work in confined spaces - is required. Staff training must

be up to date.

Legislative


Blow down pits 1.

Cleaning.

ISOLATE FROM BOILER. Drain

and thoroughly clean out.

This work must only be carried out

by a competent person and

appropriate safety precautions must

be observed. The work may be

carried out at the same time as the

boiler inspection.

12M Blow down pits

1. Cleaning.

At every thorough examination of

the associated steam boilers, or at

such intervals determined by the

competent person, the blowdown

pit should be positively isolated (i.e.

double shut-off or by blank flange)

from the boiler(s) for examination

purposes. The electrical supply to

the automated intermittent

blowdown should be locked off and

, where fitted, any compressed-air

system should be isolated and

de-pressurised. The pit should then

be drained, thoroughly cleaned out

and examined. If the quality of the

boiler feedwater is poor, the

blowdown pit may require draining

and/or cleaning more often




be observed. The work may be


boiler inspection.

12MTechnical

3. Vent pipe and

silencer (if fitted).

Check condition and ensure there

is no blockage.

If replacement or repair necessary,

advise client.

12M 3. Vent pipe and

silencer (if fitted).

Check condition and ensure there

is no blockage.

If replacement or repair necessary,

advise the client.

12MOther

Blow down tanks Note: these are pressure vessels

and as such come within the scope

of the Pressure Systems and


Regulations 2000 . See also HSE

document L101.

Blow down tanks These are pressure vessels and as

such come within the scope of the

Pressure Systems and


Regulations 2000 . See also HSE

document L101.

Other

Page 448 of 614

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1. Cleaning. ISOLATE FROM BOILER. Drain

and thoroughly clean out.




be observed. The work is normally


boiler inspection.

12M 1. Cleaning. At every thorough examination of

the associated steam boilers, or at

such intervals determined by the

competent person, the blowdown

tank should be positively isolated

(i.e. double shut-off or by blank

flange) from the boiler(s) for

examination purposes. The

electrical supply to the automated

intermittent blowdown should be

locked off and , where fitted, any

compressed-air system should be

isolated and de-pressurised. The

tank should then be drained,

thoroughly cleaned out and

examined. If the quality of the boiler

feedwater is poor, the blowdown

tank may require draining and/or

cleaning more often




be observed. The work is normally


boiler inspection.

12MTechnical

Page 449 of 614

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SANITARY, WASTE WATER PLUMBING and DRAINS48-05 48-05 SANITARY, WASTE WATER PLUMBING and DRAINS


Waste water

pipework and

traps. 1.

Condition.

Check cleanliness and ensure traps

etc. run free.

Where remedial work is required

advise client.

6M Waste water

pipework and

traps. 1.

Condition.

Check cleanliness and ensure traps

etc. run free.

Where remedial work is required

advise the client.

6MOther

Kitchen grease

traps

Inspect and remove any

accumulated grease and other

residues.

It is recommended that client should

ensure that his staff are familiar with

these traps and clean them at least

once per month and more frequently

if accumulations are severe.

1M Kitchen grease

traps

Inspect and remove any

accumulated grease and other

residues.

It is recommended that the client

should ensure that his staff are

familiar with these traps and clean

them at least once per month and

more frequently if accumulations are

severe.

1MOther

Sanitary fittings 1.

Urinals.

Inspect and clean, ensure grids on

waste are clear and outlet(s) run

freely.

6M Sanitary fittings 1.

Urinals.

Check for leaks and damage.

Check water level in cistern, adjust

float valve as necessary, check for

satisfactory cistern fill time. Check

water action around bowl rim.

Check security of all fixings and

brackets. Check function and

operation of urinal water saver unit,

ensure for correct operation/cycle

and water flow. Where dosing

system provided, check solenoid,

battery unit and operation of dosing

system generally.

6MTechnical

2. Water closets. Check condition and ensure correct

flushing and free outlet.

It is recommended that client should

ensure that his staff are familiar with

these traps and clean them at least

once per month and more frequently

if accumulations are severe.

6M 2. Water closets. Check for leaks and damage.

Check tightness of seat and flap,

flush and check water action

around bowl rim. Check water level

in cistern, adjust float valve as

necessary. Check for satisfactory

cistern fill time. Check security of all

fixings and brackets.

6MTechnical

3. Cisterns. Check operation and if necessary

replace washer on intake float

valve.

If water is running continuously

check diaphragm on siphon and

replace if necessary.

6M 4. Cisterns. Check operation and if necessary

replace washer on intake float

valve.

If water is running continuously

check diaphragm on siphon and

replace if necessary.

6MOther

4. Automatic

controls and

sensors.

Check operation. If controls are faulty refer to the

manufacturer's maintenance

instructions.

6M 5. Automatic

controls and

sensors.

Check operation. If controls are faulty refer to the

manufacturer`s maintenance

instructions.

6MOther

Soil stacks 1.

Obstructions.

Check that there are no

obstructions.

External examination should

conform to BSEN 752 - 4

6M Soil stacks

1. Obstructions.

Check that there are no

obstructions.

External examination should

conform to BS EN 752:2008

6MLegislative

Drainage 1.

Surface water

drains.

Check grates and clear of any

deposits and water flows freely.

Clear any sediments from grate

sumps. Check condition of junction

and access covers.

Advise client if any replacements

are necessary.

6M Drainage

1. Surface water

drains.

Check grates and clear of any

deposits and water flows freely.

Clear any sediments from grate

sumps. Check condition of junction

and access covers. For Rainwater

downpipes and gutters see SFG

48-07

Advise the client if any

replacements are necessary.

6MOther

Page 450 of 614

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2. Waste water

drains.

Check that drains are free from any

obstructions and that any covers

are in place and sealed. If cleaning

required ensure that H & S and

Environmental requirements are

followed.

If cleaning is required this should be

agreed with client.

2. Waste water

drains.

Carry out general inspection of all

designated drainage systems, this

should include: A). Check all waste

and rainwater discharge pipes. B).

Clean any silt build up from traps.

C). Remove inspection covers,

provide warning signs. Clean

cover(s) and frame(s). D). Observe

drainage flow in inspection

chamber and state of inspection

chamber. E). Replace cover,

cleaning out lifting keyholes, grease

and secure as necessary. F). Flush

out all drainage channels and

gulley’s.

Refer to both Environmental and

COSHH Regulations -

www.hse.gov.uk

If cleaning is required this should be

agreed with the client.

0MTechnical

3. Sinks / Basins Check basins/sinks for leaks and

damage. 2. Check traps and

overflows are free from

obstructions/soap build up etc. 3.

Check operation of taps, ensure

plug and chain are secure

6MAdded

Page 451 of 614

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AIR ADMITTANCE VALVES48-06 48-06 AIR ADMITTANCE VALVES


1. General. Air admittance valves which are

manufactured in accordance with an

Agrement certificate issued by

Board of Agrement do not normally

require maintenance.

1. General. Air admittance valves which are

manufactured in accordance with an

Agreement certificate issued by

Board of Agreement

(www.bbacerts.co.uk) do not

normally require maintenance.

Other

2. Inspection. Visually inspect externally for

mechanical damage or vandalism.

Report to client if remedial work is

required. In the event of accidental

damage or vandalism the cover can

be removed and the damaged

components or the complete

assembly replaced.

12M 2. Inspection. Visually inspect externally for

mechanical damage or vandalism.

Report to the client if remedial work

is required. In the event of

accidental damage or vandalism the

cover can be removed and the

damaged components or the

complete assembly replaced.

12MOther

Page 452 of 614

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SANITARY AND WASTE WATER PLUMBING - WATER SAVING DEVICES

and METERS

48-08 48-08 SANITARY AND WASTE WATER PLUMBING - WATER SAVING DEVICES

and METERSTitle NotesActionFQTitle FQ Action Notes

2. Hydraulic

flushing control.

Check operation and carry out

maintenance procedures in

accordance with the manufacturer's

instructions.

6M 2. Hydraulic

flushing control.


water saver unit, ensure correct

operation/cycle and water flow.

Check for correct water action

6MTechnical

3. Detection

devices.


instructions, see SENSORS.

6M 3. Detection

devices.

Check operation. Check security of

all fixings and brackets

For more detailed maintenance

instructions, see Sensors SFG 50.

6MTechnical

6. Cistern. Check warning pipe is

unobstructed.

6M 6. Cistern. Check warning pipe is

unobstructed. Check water level in

cistern, adjust float valve as

necessary, check for satisfactory

cistern fill time

6MTechnical

7. Battery (where

fitted).

Check remaining life, change as

necessary.

Replace battery according to



only in accordance with H&S and


6M 8. Battery (where

fitted).

Check remaining life, change as

necessary.

Replace battery according to



only in accordance with H&S and


6MOther

Meters 1.

Installation

Check condition. Supply meter is normally the

responsibility of the water

undertaking and should be

maintained by them.

6M Meters

1. Installation

Check condition. Record readings

in logbook

Supply meter is normally the

responsibility of the water

undertaking and should be

maintained by them.

6MTechnical

7. Dosing system

(where fitted)

Where dosing system provided,

check solenoid, battery unit and

operation of dosing system

generally.

6MAdded

Page 453 of 614

SECURITY SYSTEMS

Page 454 of 614

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SECURITY SYSTEMS-INTRUDER ALARMS49-01 49-01 SECURITY SYSTEMS-INTRUDER ALARMS

For security reasons when the client elects to have the maintenance carried out by the building

services contractor, it is suggested that the client should carry out items 1-4 at least once every three

months to ensure that the system integrity is maintained. Close circuit television (CCTV equipment),

which is usually linked into intruder alarm systems is normally maintained by specialist contractors.

For security reasons when the client elects to have the maintenance carried out by the building

services, service provider, it is suggested that the client should carry out items 1-4 at least once every

three months to ensure that the system integrity is maintained. Close circuit television (CCTV

equipment), which is usually linked into intruder alarm systems is normally maintained by specialist

service providers.

Other


8. Control Panel Check control panel internally,

check all control devices, fuse

bridges, phase barriers etc. for

signs of arcing/burning. Check all

indication lamps are working,

replace any defective lamps. Check

panel door(s) can be securely

locked and that door isolation

device is operative.

Added

1.System integrity. Carry out external examination of

installation.




12M 1.System integrity. Carry out external examination of

installation including any external

items including beacons and bells.




12MTechnical

2.Sensors and

contacts.

Carry out operational check. If

outdoors check beam systems are

not impaired by vegetation or other

obstacles.

Confirm correct operation and

sensitivity, where appropriate check

spatial configuration for volumetric

devices.

12M 2.Sensors and

contacts.

Carry out operational check. Test

each intruder detector for correct

operation and function. Check that

no obstacles have been moved

which could impair a detectors

‘view’.

External devices - check beam

systems are not impaired by

vegetation or other obstacles.

Confirm correct operation and

sensitivity, where appropriate check

spatial configuration for volumetric

devices.

12MTechnical

3.Alarm signals. Check response to signal.12M 3.Alarm signals. Check response to signal at control

panel. Reset alarm points after test.

12MTechnical

4.Sensor covers,

terminal boxes and

fixings.

Check security,Check internally for

signs of overheating, ingress of

dust and moisture.

Clean internal components with soft

brush and remove any dirt or

fluff.When replacing covers check

operation of any tamper switches

which may be fitted.

12M 4.Sensor covers,

terminal boxes

and fixings.





any flexible cables/conduits. Check

internally for signs of overheating,

ingress of dust and moisture.

Clean internal components with soft

brush and remove any dirt or fluff.

When replacing covers check

operation of any tamper switches

which may be fitted.

12MTechnical

7.Batteries 7.Batteries Check function and state of battery

charger. Check battery terminals

connections. Check that the

inter-cell connections are secure

and clean. Check state of charge.

12MTechnical

a) sealed lead

acid, b) sealed

nickel-cadmium.

Replace Batteries must be disposed of only



36M a) sealed lead

acid, b) sealed

nickel-cadmium.

Replace Batteries must be disposed of only


Environmental (www.hse.gov.uk)

Regulations.

36MOther

Page 455 of 614

SENSORS AND SWITCHING DEVICES

Page 456 of 614

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This procedure applies to all types of sensors, thermostats and requires that all safety precautions

and safe working practices be observed.

1. Check security of mountings.

2. Inspect for physical damage.

3. Check for cleanliness. Obscuration of sensors with dust can reduce sensitivity and effect the signal .

4. Check termination for tightness and corrosion - a) Electric cable,b) Pneumatic pipework.

5. Check cable/pipework locally for fixing and condition.

6. Verify correct location and installation as per manufacturer 's instructions and check for any

extraneous influences.

7. Note settings prior to commencing maintenance.

8. Check for element deterioration.

Pneumatics. Particular attention should be paid to the quality of the instrument air. Check for

contamination by dirt, oil or water.

10. All sensors should be maintained in accordance with the manufacturer's recommendations.

11. Special sensors such as are used for glycol concentration, detection of smoke and gas, together

with sensors used in water treatment may require specialist attention.

When cleaning or working in ducts it is essential that all sensors should be with withdrawn

from the duct to prevent damage. Care should also be taken to prevent any damage to linkages or

other control devices.

This procedure applies to all types of sensors, thermostats and requires that all safety precautions

and safe working practices be observed.

1. Check security of mountings.

2. Inspect for physical damage.

3. Check for cleanliness. Obscuration of sensors with dust can reduce sensitivity and effect the signal .

4. Check termination for tightness and corrosion - a) Electric cable, b) Pneumatic pipework.

5. Check cable/pipework locally for fixing and condition.

6. Verify correct location and installation as per manufacturer`s instructions and check for any

extraneous influences.

7. Note settings prior to commencing maintenance.

8. Check for element deterioration.

9. Pneumatics. Particular attention should be paid to the quality of the instrument air. Check for

contamination by dirt, oil or water.

10. All sensors should be maintained in accordance with the manufacturer`s recommendations.

11. Special sensors such as are used for glycol concentration, detection of smoke and gas, together

with sensors used in water treatment may require specialist attention.

When cleaning or working in ducts it is essential that all sensors should be with withdrawn from the

duct to prevent damage. Care should also be taken to prevent any damage to linkages or other

control devices.

Other

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PRESSURE MEASUREMENT SENSORS - static and differential50-02 50-02 PRESSURE MEASUREMENT SENSORS - static and differential


3. Operation. Check for correct operation. Check contact condition if a

pressure switch. Refer to

manufacturer s recommended

inspection procedures.

6M 3. Operation. Check for correct operation. Check contact condition if a

pressure switch. Refer to

manufacturer`s recommended

inspection procedures.

6MOther

4. Calibration. Check against Certified instrument. Refer to manufacturers

recommended calibration

procedures.

12M 4. Calibration. Check against Certified instrument

and reset as required

Refer to manufacturers


procedures.

12MTechnical

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TEMPERATURE MEASUREMENT SENSORS50-03 50-03 TEMPERATURE MEASUREMENT SENSORS


1. Sampling Check for any obstruction.12M 1. Sampling Check for any obstruction. Also

ensure the sensor is away from any

other form of heat source (radiator,

kettle photocopier) which may affect

temperature readings

Report any abnormal findings to the

client.

12MTechnical

4. Calibration. Check against Certfied instrument.12M 4. Calibration. Check against Certified instrument


12MTechnical

Outside

temperature

sensor

This should be on North Facing

surface or mechanical shaded if

not, but away from heat sources.

Report if not. Outside

temperature

sensor

This should be on North Facing

surface or mechanical shaded if

not, but away from heat sources.

Report if not.

Other



12MTechnical



12MTechnical

4.Calibration. Check against Certfied instrument.12M 4.Calibration. Check against Certified instrument


12MTechnical

3. Calibration. Check against Certfied instrument. Refer to manufacturer's


procedures.



Refer to manufacturer`s


procedures.

12MTechnical

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RELATIVE HUMIDITY SENSORS50-04 50-04 RELATIVE HUMIDITY SENSORS


1. Sampling Check for any obstruction6M 1. Sampling Check for any obstruction. Also

ensure the sensor is away from any

other source of humidity (kettle,

washing machine etc.) which may

affect humidity readings

Report any abnormal findings to the

client.

6MTechnical


and reset as necessary

12MTechnical



12MTechnical



12MTechnical

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ABSOLUTE HUMIDITY SENSORS50-05 50-05 ABSOLUTE HUMIDITY SENSORS




12MTechnical

5.Calibration. Check against Certfied instrument.12M 5.Calibration. Check against Certified instrument


12MTechnical

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CARBON DIOXIDE SENSORS50-07 50-07 CARBON DIOXIDE SENSORS




12MTechnical



12MTechnical

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VELOCITY SENSORS50-08 50-08 VELOCITY SENSORS




procedures.





procedures.

12MTechnical

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OCCUPANCY and LIGHT SENSORS50-09 50-09 OCCUPANCY and LIGHT SENSORS


3. Location. Check that sensor is not affected

by extraneous effects.

12M 3. Location. Check that sensor is not affected by

extraneous effects (i.e. shadows

from trees etc.)

12MTechnical



procedures.





procedures.

12MTechnical

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SMOKE DETECTORS50-10 50-10 SMOKE DETECTORS


1. Cleanliness. Check sensing device and where

appropriate sampling system for

cleanliness and possible

obstructions.

Refer to the manufacturer's

instructions for cleaning procedures.

12M 1. Cleanliness. Check sensing device and where

appropriate sampling system for

cleanliness and possible

obstructions.

Special attention should be paid to

areas that have had any building

works carried out to ensure smoke

heads have not been left `bagged

off` or there covers left in place. In

addition where areas have been

subject to any dusty conditions the

heads should be cleaned.

Refer to the manufacturer`s

instructions for cleaning procedures.

12MTechnical

2. Operation. Test for correct response and

operation.

Refer to manufacturer's instructions

for recommended testing

procedures. Some type of sensor

have a finite life cycle and need to

be replaced at intervals specified by

the manufacturer. Certain devices

such as ionisation detectors have no

serviceable components and should

not be exposed as a radioactive risk

may occur. Always refer to

manufacturer's instructions and

follow all recommended safety

procedures.

12M 2. Operation. Test for correct response and

operation.

Refer to manufacturer`s instructions


procedures. Some type of sensor

have a finite life cycle and need to

be replaced at intervals specified by

the manufacturer. Certain devices

such as ionisation detectors have no

serviceable components and should

not be exposed as a radioactive risk

may occur. Always refer to

manufacturer`s instructions and

follow all recommended safety

procedures. For further guidance on

testing Smoke Detectors see Fire

alarm systems SFG 22-01 and be

carried out in accordance with BS

5839 part 1:2008

12MTechnical

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GAS DETECTOR SENSORS50-11 50-11 GAS DETECTOR SENSORS

Note:- Gas detectors are specialist devices and are often designed to detect a specific gas or family of

gases, e.g. propane or butane, it is essential to refer to the manufacturer's instructions before

commencing any maintenance work on them.

Gas detectors are specialist devices and are often designed to detect a specific gas or family of

gases, e.g. propane or butane, it is essential to refer to the manufacturer`s instructions before

commencing any maintenance work on them.

Detailed guidance is provided for the maintenance of Gas Detectors in an explosive Atmosphere by

BS EN 60079-29-2:2007

technical


2. Operation. Test for correct response and

operation.

Refer to manufacturer's instructions


procedures.

12M 2. Operation. Test for correct response and

operation.

For Further Guidance See Fire

alarm systems SFG 22-01.

12MTechnical

Carbon Monoxide

Sensors

Added

Flammable Gases

and Oxygen

Sensors

It is assumed that the operational

staff will undertaken the routine

visual inspections of the installation.

Before proceeding with any

maintenance task, the operative is

to check the faults log for any

outstanding faults conditions.

Fixed gas detectors should be

included in the plant maintenance

schedule. The performance of most

detectors deteriorates with time, the

rate depending on the type of

sensor and the operating

conditions, for example a dusty,

corrosive or damp environment.

These factors will affect the

frequency of inspection,

maintenance and calibration

Repair or maintenance of fixed

apparatus (whether incorporating

single-point sensors, open path

sensors, a combination of these,

or sampling systems) should be

carried out under a control led

procedure. Defective apparatus

should be removed for repair in

a workshop outside the area being

protected. If a replacement

apparatus cannot be provided

immediately, then transport table

apparatus should be used as a

temporary substitute

Before any work is undertaken on

and sensor in a hazardous area,

ensure the notes in Hazardous

areas (electrics) SFG 27 are read

and fully understood. Ensure all

necessary local Permit to Work

procedures are fully complied with.

Added

Page 466 of 614

SEWAGE TREATMENT WORKS

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71-01 INTRODUCTORY PROCEDURES

Exposure to sewage or its products may result in a number of illnesses. These include:

1) Gastroenteritis, characterised by cramping stomach pains, diarrhoea and vomiting;

2) Weil’s disease, a flu-like illness with persistent and severe headache, transmitted by rat urine.

Damage to liver, kidneys and blood may occur and the condition can be fatal;

3) Hepatitis, characterised by inflammation of the liver, and jaundice;

4) Occupational asthma, resulting in attacks of breathlessness, chest tightness and wheezing, and

produced by the inhalation of living or dead organisms;

5) Infection of skin or eyes; and/or

6) Rarely, allergic alveolitis (inflammation of the lung) with fever, breathlessness, dry cough, and

aching muscles and joints.

If you contract the symptoms described after coming into contact with sewage, report to your doctor

immediately and advise him/her of the circumstances.

The bacteria can enter your body through cuts and scratches and through the lining of the mouth and

throat and eyes.

After having worked in sewage or anything contaminated with sewage, wash your hands and forearms

thoroughly with soap and water. If your clothes or boots are contaminated with sewage, wash

thoroughly after handling them.

Take immediate action to wash thoroughly any cut, scratch or abrasion of the skin immediately. Apply

antiseptic to the wound, cover with cotton wool or gauze, and protect with a waterproof plaster.

Do not handle food, drink or smoking materials without first washing your hands.

Sewage gases are potentially explosives and toxic. Do not enter any of the below ground

compartments of the sewage treatment plant.

Before carrying out any maintenance work, the equipment MUST be electrically isolated at the fuse

box from which the blower power supply is derived.

Do not leave covers open for any longer than necessary. Temporary barriers and warning signs

should be erected around any open covers or manways as appropriate.

Added

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71-02 SEWAGE TREATMENT WORKS - package systems


1) Air Blowers Check the operation of the

blower(s).

1WAdded

2) Diffusers Check the operation of the diffusers

(bubbles rising in the Biological

zone).

1MAdded

3) Recycle Flow Check the recycle flow into the inlet

zone. Look at the liquor being

returned, it should run clear by the

end of its cycle.

1MAdded

4) Stilling Zones Check the inlet and outlet stilling

zones are clear of debris( remove

any obstructions ).

1MAdded

5) Air Blowers Check the blower ventilation is

un-obstructed.

1MAdded

6) Filter Media Check the biomass growth on the

filter media. The biomass should be

a light brown colour, not white or

grey.

The odour in the plant should be

`earthy`. here should not be a

noticeable `rotten eggs` smell.

1MAdded

7) Effluent Check the final effluent. If this is

cloudy or contains many

suspended articles, then the humus

tank is likely to require desludging.

1MAdded

8) Pre-settlement

Tank

Inspect sludge level and remove

sludge when the level is reached as

dictated by the manufacturers

recommendations.

This frequency could be increased

to 6M depending on usage and type

of system.

12MAdded

9) Cabling, wiring

and control panel

Check all connections are tight and

that the cable is in good condition.

Check electrical door isolating

switch for correct operation. Check

cabinet door locks for correct

operation. Clean any dust/debris

away from the inside of the cabinet

with soft brush.

12MAdded

10) Inlet Pump The inlet pump must be serviced

and cleaned.

Make sure that the pump works by

checking that it pumps water into

the treatment chamber.

12MAdded

11) Overflow Alarm Clean and check for correct

operation.

12MAdded

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12) Air Blowers The air blowers must be inspected

and their condition noted. The filters

at the top of the air blowers must be

removed and cleaned. Check that

air bubbles surface evenly

throughout the system. Be aware of

abnormal noises. Replace the

filters if they cannot be cleaned

effectively.

The filters must be open and easy

to blow air through after cleaning.

12MAdded

13) Biofilm The biofilm coating on the bioblock

media must be inspected to ensure

there is a healthy level of biomass

on the media. The aeration system

and diffusers must be inspected

and the dissolved oxygen content

measured and recorded. The

bioblock media should be evenly

aerated. It is normal that the

intensity of the air bubbles differs

from one side of the system to

another.

When the system is performing

properly the bioblock media should

not need to be routinely cleaned. A

healthy level of biofilm on the media

is beneficial to increase the

available surface area and there

should be sufficient aeration coming

from the diffusers to prevent

excessive biofilm building up.

However, if the media does need to

be cleaned the level of aeration can

be increased. In severe problem

situations, the water level can be

reduced and the bioblock cleaned

with a pressure washer or the

bioblock media can be removed

cleaned and replaced.

12MAdded

14) Controls Check that the controller is

operating properly and that alarm is

triggered by loss of power to the air

blowers and pump and by high

water in the pump tank.

12MAdded

15) Water

dispersal

Inspect the system outlet to make

sure that it is flowing freely and

unimpeded from debris or

vegetation. Record any likely future

restrictions to the water outlet or

possible threats.

12MAdded

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71-03 SEWAGE TREATMENT WORKS - EXTENDED AERATION AND OXIDATION

DITCH SYSTEMSTitle NotesActionFQTitle FQ Action Notes

1. General Make general observation to ensure

proper operation of equipment.

1DAdded

2. Clarifier Remove floating sludge on clarifier

if present and clean clarifier weir.

1DAdded

3. Test & Records Check dissolved oxygen readings

for unusual values. Perform simple

cone test to give sludge

settleability; and record hours of

operation of individual processes.

A simple cone test using an Imhoff

cone may be carried out every day,

but these results must be used with

caution and will only show up

sudden changes in sludge

characteristics.

1DAdded

4. Sludge return

rate

Adjust sludge return rate and air

injection rate as necessary.

1WAdded

5. Pumps and

Motors

Alternate duty/standby

motors/pumps.

1WAdded

6. Oxygen probes Clean and calibrate dissolved

oxygen probes.

1WAdded

7. Tests Carry out chemical tests as

appropriate (COD, phosphates

etc.).

Carry out Sludge Volume Index

(S.V.I.) test.

Sludge Volume Index (S.V.I.) - the

importance of the SVI test needs to

be stressed as it gives valuable

information on sludge settleability

and it indicates if sludge needs to

be wasted.

1WAdded

8. Aerators /

blowers

Inspect aerators/blowers and

maintain as necessary.

1MAdded

9. Sludge return

pumps

Inspect and maintain inflow and

sludge return pumps.

1MAdded

10. Electrics Inspect and maintain electrical

equipment.

1MAdded

Rotating Biological

Contactors &

Percolating Filters

In general, RBCs and percolating

filter systems require less operation

and maintenance hours per week

than extended-aeration systems.

Added

11. General Examine blockage by rags etc., if

system has no screening.

Make general inspection of system

operation noting any noises from

mechanical plant.

1DAdded

12. Screens Rake screens, if applicable.1DAdded

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13. Clarifier Remove floating sludge from final

clarifiers surface.

1DAdded

14. Biofilm Examine and record biofilm

appearance (colour and thickness),

grey/black could indicate lack of

oxygen, beige/brown indicates

carbonaceous oxidation- reddish

brown indicates nitrification.

1WAdded

15. Distributor

Openings

Clean distributor openings (in

percolating filter systems).

1WAdded

16. Sludge Return sludge from clarifier to

primary settlement tank.

1WAdded

17. Percolating

Filter

Examine surface of percolating filter

for ponding.

1WAdded

18. Bearings Grease all bearings.1WAdded


appropriate (BOD, COD,

phosphates etc.).

1WAdded

20. Bearings Inspect shaft and bearings in RBC

system.

Added

21. Motors Check oil levels in motors.Added

22. Sludge return

pumps

Inspect and maintain inflow and

sludge return pumps.

1MAdded


equipment.

1MAdded

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Sequencing Batch

Reactors

These incorporate all phases of the

treatment process in one reactor

and are operated on a cyclical

basis, often incorporating several

cycles in oiie day. The phases are

operated in the following sequence:

filtration; aeration; settlement;

decanting They are high technology

systems and are generally only

used above 100 population

equivalent. Equipment includes,

pumps, aeration plant

(compressor/blower or mechanical

aerators), decanting equipment and

sludge draw off plant. Although they

are high technology systems, they

do not require sludge return and as

such their operation is simpler than

extended-aeration systems.

Added

24. General Make general observation to ensure

proper operation of equipment.

1DAdded

25. Test &

Records

Perform simple cone test to give

sludge settleability; and record

hours of operation of individual

processes.

A simple cone test using an Imhoff

cone may be carried out every day,

but these results must be used with

caution and will only show up

sudden changes in sludge

characteristics.

1DAdded

26. Blowers Check oil level of blowers if

applicable and top up if required.

Added

27. Bearings Grease all bearings1WAdded

28. Pumps and

Motors

Alternate duty/standby

motors/pumps.

1WAdded


appropriate (COD, phosphates

etc.).

Carry out S.V.I. test

1WAdded

30. Cycle times adjust cycle times to optimise

performance

1MAdded


equipment.

1MAdded

32. Sludge waste sludge as necessary.

(generally when MLSS exceeds

4500-5000, mg/l).

1MAdded

Page 473 of 614

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Constructed

Wetlands

There are two types of constructed

wetlands; horizontal flow and

vertical flow wetlands. The

horizontal flow wetlands can be

subdivided into two categories:

a) free water surface wetlands

(FWS)

b) subsurface flow system wetlands

(SFS).

Added

33. General Examine distribution pipes and

channels for blockages (especially

in secondary wetlands).

1WAdded

34. Testing Carry out chemical tests as

appropriate

1WAdded

35. System Clean out all distribution

openings/notches, lower adjustable

outlet level to flush out pipes; and

desludge primary/septic tank as

necessary (for secondary

wetlands).

1MAdded

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71-04 DRAINAGE FIELDS

BS 6297:2007+A1:2008 gives recommendations and guidance on the design and installation of

drainage fields and infiltration systems for use in wastewater treatment. BS 6297 is applicable to

systems for handling discharges from domestic and commercial sources from single households and

upwards. These sources are typically septic tanks and package treatment plants.

Added


1) Inspection Inspect drainage field to check that

it is not water logged and that

effluent is not backing up into the

upstream system.

Particular care should be taken to

avoid compaction or disturbance of

the area over and around the

drainage field.

1MAdded

Page 475 of 614

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71-05 SETTLEMENT TANKS


1. Weirs, screens,

grit channels and

storm tanks.

Clean all weirs and baffles of any

blockages or potential blockages.

Solids should be removed from

screens, grit channels and storm

tanks.

Frequency of these tasks will be set

following local risk assessment and

depending on any extreme weather

condition.

1MAdded

2. Sludge records Record sludge levels Records should be maintained of

the sludge levels in the tanks to

allow optimisation of desludging

operations and to avoid overflow of

sludges into biological zones where

treatment efficiencies can be

affected.

1MAdded

3. Pumps Maintain all system pumps in

accordance with Pumps SFG 45

sections 07, 08 and 09.

6MAdded

Page 476 of 614

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71-06 SEPERATOR SYSTEMS

Grease, light liquids and oils can cause difficulty in a wastewater treatment system. Among other

problems, grease can, coat biofilms so that they are not able to function properly. Great care should

be taken to ensure that grease and oil do not enter the system, as these contaminants may cover the

biofilm and severely limit the movement of oxygen and substrate into the biofilm.

Added


1. Grease

separators

Grease separators should be

inspected, emptied and cleaned

regularly. Attention is drawn to the

need to comply

with national or local regulations for

the disposal of waste.

For further information please refer

to BS EN 1825-2:2004

The frequency of inspection,

emptying and cleaning should be

determined with regard to the

grease and sludge storage capacity

of the separator and in accordance

with operational experience. Unless

otherwise specified, separators

should be emptied, cleaned and

refilled with clean water at least

once a month and, preferably, every

two weeks.

1MAdded

Light liquid

separators e.g. oil

and petrol

The maintenance shall be carried

out in accordance with the

manufacturers instructions.

The cleaning and maintenance

records shall be kept and made

available to the authorities upon

request and shall contain remarks

on specific events (e.g. repairs,

accidents).

For further information please refer

to BS EN 858 -2:2003

Added

2. Sludge trap Determination of sludge volume.6MAdded

3. Separator Measure the thickness of light

liquids. Check the operation of the

automatic closure device. Check

the coalescing devices for

permeability, if the water levels in

front and behind the coalescing

device show significant difference.

Check the function of the warning

device.

Emptying is recommended when

one half of the sludge volume or 80

% of the storage capacity of the

separator is reached.

6MAdded

4. Sampling Shaft Clean the drain channel. Light liquid and sludge shall be

removed as required. Before putting

in service sludge trap and separator

should be re-filled with fresh water.

6MAdded

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5. General

inspection

Empty separator system and check

for tightness of the system,

structural condition, internal

coatings [if present], condition of

inbuilt parts, state of electrical

devices and installations and

checking of adjustment of

automatic closure device, e.g.

floating bodies.

The frequency of 5 years is a

maximum and depends upon local

risk assessment.

60MAdded

Page 478 of 614

SHOWERS

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SHOWERS51-01 51-01 SHOWERS

Note: Frequency of maintenance will depend upon use and the quality of the water and should be








guidance.




Before carrying out the following procedures, consideration should be given to removing infrequently

used showers. If they are removed, the redundant supply pipework should be cut back, as far as

possible, to a common supply, for example to the recirculating pipework or the pipework supplying a

more frequently used upstream fitting.

Where it is difficult to carry out weekly flushing, the stagnant and potentially contaminated water from

within the shower and associated dead-leg needs to be purged to drain before the appliance is used.

It is important that this procedure is carried out with minimum production of aerosols, e.g. additional

piping may be used to purge contaminated water to drain.

Frequency of maintenance will depend upon use and the quality of the water and should be agreed

with the client.

Technical


3. Internal

Surfaces; tiles and

silicone joints

Check internal surfaces for cracks

in the tiles or grouting. Check all

silicone joints and seals. Rake out

damaged grout or silicone and

repair as necessary.

Generally, the day to day cleaning

of the internal surfaces should be

undertaken by the clients staff.

Cracks or chips in the surfaces can

be a breeding ground for bacteria.

3MAdded

Valves See - VALVES. Valves and

Thermostatic

mixing valves

See Valves SFG 06Technical

1. Outlet sprays. Remove, clean spray heads. Check

adjustable sprays (if fitted).

Take care not to damage spray

outlet holes. More often in hard

water areas

3M 1. Outlet sprays. Dismantle, clean spray heads and

descale spray heads. Check

adjustable sprays (if fitted).

Quarterly or as necessary

Take care not to damage spray

outlet holes. More often in hard

water areas

3MTechnical

2. Body jets. Remove, clean spray heads. Adjust

water flow rates.

More often in hard water areas3M 2. Body jets. Dismantle, clean jet heads and

descale body jets. Adjust water flow

rates. Quarterly or as necessary

More often in hard water areas3MTechnical

3. Flexible hoses. Remove, clean. Check joints and

flexible covering for damage.

Report to client if replacement

recommended. More often in hard

water areas

3M 3. Flexible hoses. Dismantle, clean. And descale

hoses. Check joints and flexible

covering for damage. Quarterly or

as necessary

Report to client if replacement

recommended. More often in hard

water areas

3MTechnical

Page 480 of 614

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SHOWERS BOOSTER PUMPS51-02 51-02 SHOWERS BOOSTER PUMPS









guidance.




Before carrying out the following procedures, consideration should be given to removing infrequently

used showers. If they are removed, the redundant supply pipework should be cut back, as far as

possible, to a common supply, for example to the recirculating pipework or the pipework supplying a

more frequently used upstream fitting.

Where it is difficult to carry out weekly flushing, the stagnant and potentially contaminated water from

within the shower and associated dead-leg needs to be purged to drain before the appliance is used.

It is important that this procedure is carried out with minimum production of aerosols, e.g. additional

piping may be used to purge contaminated water to drain.


with the client.

Technical


2. Motor electrical

terminals.

Inspect and tighten if required.12M 2. Electrical. Check condition of local isolator,

open and clean if required. Remove




dampness. Carry out the following

tests to all pumps and record

results:-a. Insulation resistance test

on wiring and motors. b. Earth loop

impedance test on case or frame of

units. c. Load test on motors (start

and run current). Compare results

with manufacturer’s specification.

Check that power lead at motor are

undamaged and are securely held.

12MTechnical

3. Motor. Clean and check. See MOTORS.12M 3. Motor. Clean and check. See Motors SFG3912MTechnical

7. Water filters. Remove and clean/replace. Or as manufacturers specification6M 7. Water filters. Remove, clean and descale.

Replace as necessary.

Or as manufacturers specification6MTechnical

Page 481 of 614

SMOKE EXTRACT

Page 482 of 614

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Reason For

Change

SMOKE RELIEF - and/or natural fire ventilators52-02 52-02 SMOKE RELIEF - Natural smoke and heat exhaust ventilators

Frequency of maintenance and testing for smoke relief ventilators should conform to BS EN

12101-2:2003 Smoke and heat control systems and should be in accordance with local

authority requirements.

Maintenance and testing for smoke relief ventilators should conform to BS (www.bsi-global.com) EN

12101-2:2003 Smoke and heat control systems and should be in accordance with local authority

requirements.

Other


1. Fixing and

weathering.

Check condition and clean off any

dirt with stiff (not wire) brush from

internal and external weathering

channels.

In very dirty or aggressive

environments, more frequent

attention may be necessary.

12M 1. Fixing and

weathering.

Check condition and clean all dirt

from internal and external

weathering channels and surfaces

of the ventilator (take precautions to

prevent inhalation of bird droppings

- COSHH Regulations) with stiff

(not wire) brush.

In very dirty or aggressive

environments, more frequent

attention may be necessary.

12MTechnical

2. Louvres/flaps

or dampers.

Clean bearings and lubricate as

necessary.

12M 2. Louvers/flaps

or dampers.


necessary.

Only use lubricant as recommended

by manufacturer

12MTechnical

4. Operating

mechanism.

Check action. Report to client if repairs or

replacement required.

12M 4. Operating

mechanism.

Check action for smooth operation

and to ensure they open and close

correctly. Lubricate all linkages in


recommendations.


by manufacturer. Report to client if

repairs or replacement required.

12MTechnical

5. Smoke vents. Check condition and test weekly

and record as required by BS 7346,

and the Fire Precautions

(Workplace) Regulations

1997. Refer to www.hse.gov.uk for

detail.

Client to advise if weekly tests are to

be included within maintenance

contract.

1W 5. Smoke vents. Check condition and test weekly

and record as required by BS 7346,

Regulatory Reform (Fire Safety)

Order 2005 and the Fire Precaution

(Work force) Regulation 1997.


Client to advise if weekly tests are to

be included within maintenance

contract.

1WOther

Page 483 of 614

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Reason For

Change

SMOKE RELIEF - Powered fire ventilators52-03 52-03 SMOKE RELIEF - Powered smoke and heat exhaust ventilators



requirements.

Added


10. Operating

mechanism.

Check action for smooth operation

and to ensure they open and close

correctly. Lubricate all linkages in


recommendations


by manufacturer. Report to client if

repairs or replacement required.

12MAdded

11. Louvers/flaps

or dampers.


necessary.


by manufacturer

12MAdded

12. Compressor

(where applicable)

Carry out tasks as directed in

relevant section.

Check rails are clear of any

obstruction so that the curtain will

drop into place when required.

The client should carry out this task

as part of their fire alarm testing

once every week to ensure that the

system integrity is maintained.

See Pipework systems SFG40-08

Added

1. Electricity

supply.

Isolate in accordance with HSAWA

safety requirements. Refer to

www.hse.gov.uk for detail.

Note: Ensure clients is aware that

system or part of system is

inoperative during execution of

maintenance.

12M 1. Electricity

supply.

Isolate in accordance with HSAWA

safety requirements. Refer to

www.hse.gov.uk for detail.

Ensure client is aware that system

or part of system is inoperative

during execution of maintenance.

12MOther

2. Filters. See FILTERS.12M 2. Filters. See Filters SFG2112MTechnical

3. Fixings Clean fixing and weathering and

clean off all dirt from external

surfaces of ventilator.

Use brush for dirt removal.12M 3. Fixing and

weathering.


from internal and external

weathering channels and surfaces

of the ventilator (take precautions to

prevent inhalation of bird droppings

- COSHH Regulations) with stiff

(not wire) brush.

Use brush for dirt removal.12MOther

4. Fan impeller of

motor.

Clean impeller and rotor and check

ease of rotation and correct

direction of rotation.

It is important to check for correct

clearance between fan shrouds and

impeller.(See also MOTORS)

12M 4. Fan impeller of

motor.

Clean impeller and rotor and check

ease of rotation and correct

direction of rotation.

It is important to check for correct

clearance between fan shrouds and

impeller.(See also Motors SFG39)

12MOther

8. Test and run. Test weekly and record same as

required by BS 7346.

Note: Client is to advise whether

weekly test is to form part of the

maintenance contract.

1W 8. Test and run. Test weekly and record same as

required by BS 7346.

Ensure client is aware that system

or part of system is inoperative

during execution of maintenance.

1WOther

9. Controls. Check action. See CONTROLS for detailed

maintenance.

12M 9. Controls. Check action. See Control panel and controllers

SFG 14 for detailed maintenance.

12MTechnical

Page 484 of 614

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Change

SMOKE CURTAINS52-04 52-04 SMOKE CURTAINS



requirements.

Added


b) guide rails

(where fitted)


obstruction.

12M b) guide rails

(where fitted)


obstruction so that the curtain will

drop into place when required.

The client should carry out this task

as part of their fire alarm testing

once every week to ensure that the

system integrity is maintained.

12MTechnical

3. Compressor

(where applicable)

See relevant section. 3. Compressor

(where applicable)

Carry out tasks as directed in

relevant section.

See Pipework systems SFG40-08Technical

Page 485 of 614

SOLAR PANELS

Page 486 of 614

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Reason For

Change

SOLAR HOT WATER PANELS and similar COLLECTING DEVICES53-01 53-01 SOLAR HOT WATER PANELS and similar COLLECTING DEVICES

Working at heights should be in strict accordance with the Work at Height Regulations 2005Added


Plate type

collectors 1. Glass

cover plate.

Clean and report condition if

cracked. A safe method of gaining

height may be required; staff are to

be fully trained.

Frequency will depend on location

and local atmospheric condition. Dirt

causes loss of collector efficiency.

Cracked glass should be replaced.

6M Plate type

collectors

1. Glass cover

plate.


from surfaces of the unit (take

precautions to prevent inhalation of

bird droppings - COSHH

Regulations) with stiff (not wire)

brush. report condition if cracked

A safe method of gaining height

may be required; operatives are to

be fully trained.


and local atmospheric condition.

Dirt causes loss of collector

efficiency. Cracked glass should be

replaced.

6MTechnical

Vacuum tube type

1. Tubes.

Clean and report condition if

cracked.




Cracked tubes should be replaced.

6M Vacuum tube type

1. Tubes.


from surfaces of the tubes (take

precautions to prevent inhalation of

bird droppings - COSHH

Regulations) with stiff (not wire)

brush. report condition if cracked.

A safe method of gaining height


be fully trained.




efficiency. Cracked tubes should be

replaced.

6MTechnical

2. Reflectors. Clean and report condition if

cracked.




Care should be taken to avoid

damaging the reflector surface.

6M 2. Reflectors. A safe method of gaining height


be fully trained.




efficiency. Care should be taken to

avoid damaging the reflector

surface.

6MOther

6. Anti-freeze

solution.

Replace anti-freeze solution.36MAdded

6. Anti-freeze

solution.

Replace anti-freeze solution.36MAdded

Page 487 of 614

SPLIT SYSTEMS INCLUDING HEAT PUMPS

Page 488 of 614

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Unit type air coolers, generally known as unit type air conditioners are stand alone pieces of

equipment, the bulk of the equipment being factory assembled, sometimes needing only an electrical

supply and in some instances water/drainage connections to make them work. Size can vary between

2 and 100kW of cooling. It follows that such units will contain some or all of the elements covered in

other sections of this specification and when maintenance is carried out reference should be made to

the appropriate section(s). It may be efficient for small units to be serviced at a central workshop.

This unit can be divided into two main categories namely:-

a) one piece

b) split two piece

They are variously known as cassettes, wall or window, ducted or portable, multi-splits, console

through wall, or free standing.

With the split systems pipework is necessary on site to connect the room unit to the condenser unit

together with charging up and commissioning. Increased maintenance may be required with these

compact units because of the density of the components.

Where there is a requiements to connect or dis-connect refrigerant lines, including snap connections,

the law demands that only a REFOM or other mandatory scheme provider registered engineer is

permitted to do this work.

The only difference between a Heat pump and a Split Air conditioning unit is that a heat pump has a

reversing valve to switch the unit from cooling mode to heating mode. The reversing valve changes

the direction of refrigeration flow, making the outdoor condenser the evaporator and the indoor unit

the condenser. The outdoor unit needs frost protection to switch back over when the condenser

freezes.

Where Oxygen Free Nitrogen is used, a Risk Assessment must be carried out prior to use.

Unit type air coolers, generally known as unit type air conditioners are stand alone pieces of

equipment, the bulk of the equipment being factory assembled, sometimes needing only an electrical

supply and in some instances water/drainage connections to make them work. Size can vary between

2 and 100kW of cooling. It follows that such units will contain some or all of the elements covered in

other sections of this specification and when maintenance is carried out reference should be made to

the appropriate section(s). It may be efficient for small one piece free standing units to be serviced at

a central workshop.

Units can be divided into two main categories namely:-

a) one piece

b) split two piece

They are variously known as cassettes, ceiling, ceiling suspended, wall or window mounted, side

blow, ducted, portable, multi-splits, console through wall, or free standing.

With the split systems pipework is necessary on site to connect the room unit to the condenser unit

together with charging up and commissioning. Increased maintenance may be required with these

compact units because of the density of the components.

Where there is a requirement to connect or disconnect refrigerant lines, including snap connections,

must have a suitable refrigerant handling qualification and the F Gas regulations demands that only

an engineer who is in possession of full F-gas certification is permitted to carry these works out.






system type.













minimum frequency.

The only difference between a heat pump and a split air conditioning unit is that a heat pump has a

reversing valve to switch the unit from cooling mode to heating mode. The reversing valve changes

the direction of refrigeration flow, making the outdoor condenser the evaporator and the indoor unit

the condenser. The outdoor unit needs frost protection to switch back over when the condenser

freezes.

Where Oxygen Free Nitrogen is used, a Risk Assessment must be carried out prior to use and

suitable training given.

Technical

Page 489 of 614

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SPLIT SYSTEMS – air-cooled with direct expansion evaporator (DX), with

gas, hot water or elec. htrs

54-02 54-02 DX SPLIT SYSTEMS - with gas, electric or hot water heaters

These are primarily two units with either integral or remote air-cooled condensers working with direct

expansion coolers, primarily for room air conditioning applications. The frequency of servicing or

cleaning will depend upon the working environment and the amount of usage.

These are primarily two units with either integral or remote air-cooled condensers working with direct

expansion coolers, primarily for room air conditioning applications. The frequency of servicing or

cleaning will depend upon the working environment and the amount of usage.

Service providers working on these systems must be registered to an approved Certified Scheme

provider, in accordance with the "F" Gas and Building Regulations






system type.













minimum frequency.

Technical


3. Refrigerant. 3. Refrigerant. Service providers must registered

to an approved Certified Scheme



Technical

a) charge. Check level in receiver and/or liquid

line sight glass.

Note: Any shortfall or frequent

topping up may indicate leakage

and must be reported to client.

6M a) charge. Check level in receiver and/or liquid

line sight glass.

Any shortfall or frequent topping up

may indicate leakage and must be


6MOther

b) leaks Test accessible parts of system. Pay particular attention to bolted

and flare connected joints, sight

glass glands and any pressure relief

valve vent to atmosphere. Note:

any removed refrigerant (CFC)

must be recovered and not

released to atmosphere.

Only a REFCOM, or other

mandatory scheme

provider registered engineer must

work on this equipment.

6M Deleted

Page 490 of 614

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4. Condenser and

evaporator fins.

Check for damage and/or dust

accumulation. Clean as necessary.

Do not use CFC’s (refrigerant) for

cleaning tubes use dry nitrogen or


required. A Risk Assessment is

required prior to using Nitrogen.

6M 4. Condenser and

evaporator fins.


accumulation. Clean and comb coil

fins, vacuum unit internally.








given.

6MTechnical

5. Fans and

motors and

damper drive

motors (if fitted).

Check bearings and lubricate as

necessary. Inspect and check on

fan guard covers and inspection

plates.

Where appropriate check drive belts

for condition and tension. Adjust or

replace as necessary. Ensure that

all bolts, screws etc. are in place

and tight. (See also MOTORS)

6M 6. Fans and

motors and

damper drive

motors (if fitted).




plates.





and tight. See also Motors SFG39.

6MTechnical

6. Evaporator and

drains, dip tray

and pump.

Check and clean. Check

condensate drain is clear and

clean.

Sterilisation may be required.6M 7. Evaporator

[Indoor],drains,

drip tray and

pump.

Check, flush and clean. Check


clean. Check operation of

condensate pump (if fitted)

Sterilisation of drip tray and drain

may be required.

6MTechnical

7. Compressor

capacity control

and unloaded start

valves (if fitted).

Check for correct operation. Check

motor current against

commissioning data.

Compressor unload on start should

reduce and increase capacity on

demand.

6M 8. Compressor

capacity control

and unloaded start

valves (if fitted).



commissioning data or nameplate.



demand.

6MTechnical

8. Refrigerant

pipework.

Check for vibration and rectify any

loose or inadequate support/fixing.

All pipework joints should be brazed

or welded. To prevent internal

scaling use dry, oxygen free

nitrogen (OFN) during the jointing

process. A Risk Assessment must

be done prior to using Nitrogen.

6M 9. Refrigerant

pipework.

Check entire refrigerant pipework

run. Ensure pipes are secure.



scaling use dry, oxygen free



be done prior to using Nitrogen.

6MTechnical

9. Filters. Check condition and replace as

necessary.

6M 10. Filters. Check condition and replace as

necessary.

Frequency to be determined

depending on conditions. It is

however important to clean the filter

prior to it becoming clogged. This

can affect the energy efficiency of

the unit by as much as 10% and can

also allow dirt to become clogged

into the evaporator coil.

6MTechnical


as necessary.

6M 11. Insulation. Check condition. Repair and reseal

as necessary.

6MOther

11. General

cleanliness.

Clean surfaces of compressor and

components of condensing unit.


vicinity of plant.

6M 12. General

cleanliness.


components of condensing unit

particularly fan impeller and motor

casing. Check and clean surfaces


repair and treat as found necessary


vicinity of plant.

6MTechnical

Page 491 of 614

Previous

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Reason For

Change



connections. Isolate local control

panel and inspect for signs of



If main fuse carrier connections to

compressors show any discoloration

they must be changed.

6M 13. Electrical. Check for satisfactory operation of









bonding is secure.



they must be changed.

6MTechnical

13. System

operation.

Confirm that it is in accordance with

design parameters.





6M 14. System

operation.










ensure for air tight seal. Check that

unit is maintaining space conditions





6MTechnical

1. Gas Fired. See relevant BURNER section.6M 1. Gas Fired. See relevant Burner SFG 07

section.

6MTechnical

2. Hot water

supply.

See relevant HEAT EMITTER

section. Check for leaks. Check

anti-freeze protection on heating

coil.

6M 2. Hot water

supply.

See relevant Heat emitter SFG 28



coil.

6MTechnical

5. Condenser –

general

Check all nuts, (including holding

down bolts) bolts, setscrews, etc.

for security. Check any drip tray for

blockage/leaks etc. Remove any

debris and clean.

6MAdded

b) leaks Check refrigerant Charge,

recharge/report as found

necessary. Check Joints, valves

including stems, seals, including

seals on replaceable driers and

filters, parts of the system subject

to vibration, connections to safety

or operational devices of the

equipment or system. Examine for

leakage using direct or indirect

measuring methods.



attendants.

Any removed refrigerant (CFC) must

be recovered and not released to

atmosphere.






6MAdded

A) Normal

systems:

<3 kg




0MAdded




12MAdded

Page 492 of 614

Previous

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Reason For

Change




6MAdded




3MAdded

E) Hermetically

sealed systems:

<6 kg




0MAdded




12MAdded




6MAdded




3MAdded

Page 493 of 614

Previous

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Reason For

Change

SPLIT SYSTEMS/ HEATPUMPS – air-cooled with direct expansion

evaporator (DX)

54-03 54-03 SPLIT SYSTEMS/ HEATPUMPS – air-cooled with direct expansion

evaporator (DX)

Engineers working on these systems must belong to an approved Certified Scheme provider, in

accordance with the "F" Gas and Building Regulations






system type.













minimum frequency.

Added


A) Normal

systems:

<3 kg




0MAdded




12MAdded




6MAdded




3MAdded

E) Hermetically

sealed systems:

<6 kg




0MAdded




12MAdded




6MAdded

Page 494 of 614

Previous

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Reason For

Change




3MAdded

5. Condenser –

general

Check all nuts, (including holding

down bolts) bolts, setscrews, etc.

for security. Check any drip tray for

blockage/leaks etc. Remove any

debris and clean.

6MAdded

3. Refrigerant. 3. Refrigerant. Service providers must registered

to an approved Certified Scheme



Technical

a) charge. Check level in receiver and/or liquid

line sight glass.

Note: Any shortfall or frequent

topping up may indicate leakage

and must be reported to client.

6M a) charge. Check level in receiver and/or liquid

line sight glass.

Any shortfall or frequent topping up

may indicate leakage and must be


6MOther

b) leaks Test accessible parts of system. Pay particular attention to bolted

and flare connected joints, sight

glass glands and any pressure relief

valve vent to atmosphere. Note: any

removed refrigerant (CFC) must be


atmosphere. Only a REFCOM or

other mandatory scheme

provider registered engineer must

work on this equipment.

6M b) leaks Check refrigerant Charge,










measuring methods.



attendants.

Any removed refrigerant (CFC) must

be recovered and not released to

atmosphere.






6MTechnical

4.Condenser and

evaporator fins.


accumulation. Clean as necessary.

Do not use CFC s (refrigerant) for

cleaning tubes use dry nitrogen or


required. A Risk Assessment must

be done prior to use.

6M 4.Condenser and

evaporator fins.


accumulation. Clean and comb coil

fins, vacuum unit internally








given.

6MTechnical

5. Fans and

motors and

damper drive

motors (if fitted).




plates.





and tight.

6M 6. Fans and

motors and

damper drive

motors (if fitted).




plates.





and tight.

6MOther

6. Evaporator

and drains, dip

tray and pump.

Check and clean. Check


clean.

Sterilisation may be required.6M 7. Evaporator

and drains, drip

tray and pump.

Check, flush and clean. Check


clean. Check operation of

condensate pump (if fitted).

Sterilisation of drip tray and drain

may be required

6MTechnical

7. Compressor

capacity control

and unloaded start

valves (if fitted).



commissioning data.



demand.

6M 8. Compressor

capacity control

and unloaded start

valves (if fitted).



commissioning data or nameplate.



demand.

6MTechnical

Page 495 of 614

Previous

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Reason For

Change

8. Refrigerant

pipework.

Check for vibration and rectify any

loose or inadequate support/fixing.



scaling use dry, oxygen free,




6M 9. Refrigerant

pipework.

Check entire refrigerant pipework

run. Ensure pipes are secure, not

sagging is in good repair.



scaling use dry, oxygen free,




6MTechnical

9. Filters. Check condition and replace as

necessary.

6M 10. Filters. Check condition and replace as

necessary.

Frequency to be determined

depending on conditions. It is

however important to clean the filter

prior to it becoming clogged. This

can affect the energy efficiency of

the unit by as much as 10% and can

also allow dirt to become clogged

into the evaporator coil.

6MTechnical


as necessary.

6M 11. Insulation. Check condition. Repair and reseal

as necessary.

6MTechnical

11. General

cleanliness.


components of condensing unit.


vicinity of plant.

6M 12. General

cleanliness.


components of condensing unit

particularly fan impeller and motor

casing. Check and clean surfaces


repair and treat as found

necessary.


vicinity of plant.

6MTechnical



connections. Isolate local control

panel and inspect for signs of





they must be changed. Pay

particular attention to contactors and

terminals including all thermistor

controls in compressor terminal box.

6M 13. Electrical. Check for satisfactory operation of









bonding is secure.



they must be changed. Pay

particular attention to contactors and

terminals including all thermistor

controls in compressor terminal box.

6MTechnical

13. System

operation.

Confirm that it is in accordance with

design parameters.





6M 14. System

operation.










ensure for air tight seal. Check that

unit is maintaining space

conditions.





6MTechnical

14. Gas Fired. See relevant BURNER section.6M 15. Gas Fired. See relevant Burner SFG 07

section.

6MTechnical

15. Hot water

supply.

See relevant HEAT EMITTER



coil.

6M 16. Hot water

supply.

See relevant Heat emitter SFG 28



coil.

6MTechnical

Page 496 of 614

STARTERS

Page 497 of 614

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Reason For

Change

DRIVE ELEMENTS - STARTERS55-01 55-01 DRIVE ELEMENTS - STARTERS

Note: Before carrying out any work on electrical equipment, check status and isolate in accordance

with HASAWA and Electricity at Work Act requirements.

Before carrying out any work on electrical equipment, check status and isolate in accordance with

HASAWA and the Electricity at Work Regulations 1989 requirements.

Other

Page 498 of 614

Previous

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Reason For

Change

STARTERS - Star Delta55-02 55-02 STARTERS - Star Delta



Added


1.Switchgear. Carry out maintenance procedures

as per power contactors.

See CONTROL PANELS .12M 1.Switchgear. Carry out maintenance procedures


See Control panels and controllers

SFG 14

12MTechnical

3.Start up

sequence.

Check for correct sequence from

start up. Inspect check and adjust

setting of timer to match character

of the connected load.

'Star' first then 'Delta' mode.12M 3.Start up

sequence.

Check for correct sequence from

start up. Inspect check and adjust

setting of timer to match character

of the connected load.

Star` first then `Delta` mode.12MOther

Page 499 of 614

Previous

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Reason For

Change

STARTERS -Two speed - Dual wound55-03 55-03 STARTERS -Two speed - Dual wound


HASAWA and the Electricity at Work Regulations 1989

Added




See CONTROL PANELS.12M 1.Switchgear. Carry out maintenance procedures



SFG 14

12MTechnical

4.Overloads. Check both high and low overloads.12M Deleted

Page 500 of 614

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Reason For

Change

STARTERS - Two speed - Pole change55-04 55-04 STARTERS - Two speed - Pole change



Added







SFG 14

12MTechnical

Page 501 of 614

Previous

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Version

Reason For

Change

STARTERS - Reversing55-05 55-05 STARTERS - Reversing



Added







SFG 14

12MTechnical

Page 502 of 614

Previous

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Reason For

Change

STARTERS - Auto-transformer55-06 55-06 STARTERS - Auto-transformer



Added







SFG 14

12MTechnical

Page 503 of 614

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Reason For

Change

STARTERS - Quick transition, electric heater55-07 55-07 STARTERS - Quick transition, electric heater



Added







SFG 14

12MTechnical

Electric Heater

Type 1. Electrical

connections.

Check.12M Electric Heater

Type

1. Electrical

connections.

Check.12MTechnical

Page 504 of 614

Previous

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Version

Reason For

Change

STARTERS electrolyte type55-08 55-08 STARTERS electrolyte type



Added

Page 505 of 614

Previous

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Reason For

Change

STARTERS-AIR BREAK AND CONTACTORS55-09 55-09 STARTERS-AIR BREAK AND CONTACTORS

Before carrying out any work on control panel isolate mains supply at the distribution board. Before carrying out any work on control panel isolate mains supply at the distribution board.



Technical


b)oil dashpot, If oil is cloudy or sludge has

formed, clean out dashpot with

solvent and refill.

12M b)oil dashpot, If oil is cloudy or sludge has

formed, clean out dashpot with

solvent and refill.

Refill with oil in accordance with


12MTechnical

12. Fuses (if

fitted).

Check for correct rating and type. e.g. rewirable fuses have not been

installed in the carriers designed for

cartridge fuses.

12M 12. Fuses (if

fitted).

Check for correct rating and type. e.g. check that re-wirable fuses

have not been installed in the

carriers designed for cartridge

fuses.

12MTechnical

b)after return to

service.

Check that any meters and pilot

lights fitted function correctly.

12M b)after return to

service.

Check that any meters and

indicator lights fitted function

correctly.

12MTechnical

Page 506 of 614

STORAGE TANKS

Page 507 of 614

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Whilst legionella bacteria are most active in the temperature range 20°C to 45°C, occasions can occur

where growth is promoted even in cold water systems. This can arise where the local temperature is

raised by:

a) heat build up due to solar gain or the proximity to hot water services, or

b) the storage capacity is far greater than is necessary. In general terms the storage capacity should

not exceed one day's usage

c) seasonal variations. In the summertime it is not unusual to have incoming mains supplies

exceeding 20°C. When this occurs the systems should be reassessed with the likely outcome of

increasing regular flushing to these outlets in a safe manner with minimal aerosolation.

Cleanliness of the system is of primary importance to ensure that the legionella bacteria do not have

any nutrients for growth and survival. Such nutrients can come from vegetable, animal and even

mineral substances and it is for this reason that storage cisterns must be free from rust, dust, slime,

mould, fungi and such items as dead birds, rats, mice, insects etc. and that non metallic materials

satisfy the requirements of BS 6920. Lists of materials approved by the water industry (WRAS) are

published in the Water Fittings and Materials Directory (see Standards List). All new and replacement

water fittings must satisfy Water Supply (water fittings) Regulations 1999 requirements and be listed in

the WRAS directory. (WRAS Simple Steps to Approval)

Cleansing of tanks, cisterns and associated pipe work must be followed by full disinfection in

accordance with the procedures laid down in BS 6700 Rev 2006 and as per chemical


Cisterns must have close fitting lids, which should not be of timber or other porous materials. Lids

must have vent pipes of adequate cross section to prevent suction developing on water draw off . All

vent pipes and overflows must be fitted with close mesh to prevent the ingress of foreign matter.

These must be checked annually and cleaned if necessary.

The pipe-work system must be free of any points where pockets of dirt, slime or sediment can build

up.

The need for full disinfection of Cisterns and associated down services is outlined in HSE's L8 part 2

Guidance page 48 paragraph 190.

WARNING: Subject to age, there are still many items lagged with Asbestos, if uncertain - STOP

WORK. A Certified Test Result MUST be obtained prior to consideration to proceed.






guidance.




Guidance note L101 Safe work in confined spaces 1997. Approved code of practice, regulations and

guidance 2nd edition (2009).



raised by:



not exceed one day`s usage








satisfy the requirements of BS (www.bsi-global.com) 6920. Lists of materials approved by the water

industry (WRAS (www.wras.co.uk)) are published in the Water Fittings and Materials Directory (see

Standards List). All new and replacement water fittings must satisfy Water Supply (water fittings)

Regulations 1999 requirements and be listed in the WRAS directory. (WRAS Simple Steps to

Approval)


accordance with the procedures laid down in BS 6700 Rev 2006 [partially superseded by BS EN

806-4:2010] and as per chemical manufacturers specification.






up.

The need for full disinfection of Cisterns and associated down services is outlined in HSE`s L8


WARNING: Subject to age, there are still many items lagged with Asbestos, if uncertain -

Technical

Page 508 of 614

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STOP WORK. A Certified Test Result MUST be obtained prior to consideration to proceed.

Page 509 of 614

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COLD WATER STORAGE TANKS and CISTERNS56-02 56-02 COLD WATER STORAGE TANKS and CISTERNS

Note: Cisterns operate at atmospheric pressure whereas tanks are sealed vessels operating at

pressures above atmospheric.






guidance.




Guidance note L101 Safe work in confined spaces 1997. Approved code of practice, regulations and

guidance 2nd edition (2009).



raised by:



not exceed one day`s usage








satisfy the requirements of BS (http://www.bsi-global.com) 6920. Lists of materials approved by the

water industry (WRAS ) are published in the Water Fittings and Materials Directory (see Standards

List). All new and replacement water fittings must satisfy Water Supply (water fittings) Regulations

1999 requirements and be listed in the WRAS directory. WRAS Simple Steps to Approval


accordance with the procedures laid down in BS 6700 Rev 2006 [partially superseded by BS EN

806-4:2010] and as per chemical manufacturers specification.






up.

The need for full disinfection of Cisterns and associated down services is outlined in HSE`s L8


WARNING: Subject to age, there are still many items lagged with Asbestos, if uncertain -

STOP WORK. A Certified Test Result MUST be obtained prior to consideration to proceed.

Technical

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1. General Check for adequate water level and

where provided, check tank warning

pipe for signs of discharge. Inspect

tank for evidence of leaks and

corrosion.

3MAdded

14. Earthing and

bonding

Where pipework, fittings or

appliances are to be replaced,

continuity of earthing and

equipotential bonding shall be

maintained. Where pipework has

been used for earthing, alternative

earthing arrangements shall be

made in accordance with BS 7430

by a competent person. Where

there is no evidence of main

equipotential bonding, which may

be required, the installer should

inform the responsible person that

any bonding should be checked

and remedied where necessary by

a competent person.

12MAdded

1. Float operated

ball valve




and security.


ball valve


shut off. Replace washer and / or

defective parts if necessary. Check

float for leakage and security.

3MTechnical

2. Level control

switches (if fitted).

Check for scale deposits, clean as

necessary and check operation.

For specialist maintenance of level

control switches see LEVEL

SWITCHES.

6M 3. Level control

switches (if fitted).

Check for scale deposits, clean as

necessary and check function and

operation of level switches, by

simulating water level condition,

ensure correct operation of

associated plant

For specialist maintenance of level

control switches see Level switches

SFG 58.

6MTechnical

3. Cistern or tank

body.

Check for leaks and any structural

weaknesses.

Ensure that any brackets, etc.

supporting the tank are firmly fixed.

6M 4. Cistern or tank

body.

Check for leaks and any structural

weaknesses.

Ensure that any brackets, etc.

supporting the tank are firmly fixed.

6MOther

4. Valves Check valve stems are free to turn. Ensure that any insulation or trace

heating cable removed during

inspection is replaced or frost

damage could ensue.

6M 5. Valves Note settings of tank valves

(excluding DRV`s). Check, rotate

handwheel sufficiently to indicate

that wedge is not seized in closed

position nor jammed in open

position. If normally open, close

valve and reopen. When fully open,

close valve 1/2 turn to ensure valve

does not jam.

Ensure that any insulation or trace

heating cable removed during

inspection is replaced or frost

damage could ensue.

See Valves SFG 61

6MTechnical

5. Air vents and

overflow screens.

Check for blockage and condition. Clean when necessary. Report if

replacement needed.

6M 6. Air vents and

overflow screens.

Check tank air vents are clean and

unobstructed, where filters are

provided remove clean and/or

replace as found necessary.

Clean when necessary. Report if

replacement needed.

6MTechnical

6. Insulation. Check condition, replace if

necessary.

Look for any damp patches, if

necessary removing insulation to

find cause.

6M 7. Insulation. Check condition, replace if

necessary.

Look for any damp patches, if

necessary removing insulation to

find cause.

6MOther

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7. Manlid and

access covers.

Check condition of seals. If lid has been removed for

inspection purposes ensure seals

are effective.

12M 8. Manlid and

access covers.

Check condition of seals.

Check Lids, inspection cover(s) etc.

can be correctly located and made

secure.

If lid has been removed for

inspection purposes ensure seals

are effective.

12MTechnical

8. Cistern or

tanks.

Inspect and report cleanliness and

condition. The use of a matrix to

substantiate reasons for cleaning

and continuity between inspecting

personel would be advantageous.

Check overflow and warning pipes

are unobstructed, sized correctly

and that the ends are conspicuous

and well above the flood over level

of a gully and conform to the water

regulations. If any remedial work

needs to be carried out, advise

client. If painting is required any

paint should be non-toxic and WRC

Water Byelaws Scheme/Water

Supply (water fittings) Regulations

1999 WRAS approved.

12M 9. Cistern or

tanks.

All cold water storage cisterns and

cold feed cisterns must be

examined at least annually, paying

particular attention to the presence

of foreign objects, biological

material and excessive corrosion.

On completion of the examinations,

the cisterns should be cleaned, if

required, and any remedial work

carried out. Before the cisterns and

system are put back into use, they

should be disinfected in accordance

with the procedure detailed in

Chapter 17 of Part A.

Carry out full biological testing of

water and report.

Check atmosphere within tank prior

to entry.

Check overflow and warning pipes

are unobstructed, sized correctly

and that the ends are conspicuous

and well above the flood over level

of a gully and conform to the water

regulations. If any remedial work

needs to be carried out, advise

client. If painting is required any

paint should be non-toxic and WRC

Water Byelaws Scheme/Water

Supply (water fittings) Regulations

1999 WRAS approved.

SEE HTM 04 Part A chapter 17 All

cisterns should be internally cleaned

to remove all visible dirt and debris.

Cisterns and distributing pipework

should be drained, filled with fresh

water

and then drained completely. The

cisterns should then be refilled and

the supply servicing valves closed.

On re-fitting it is normal practice to

add high doses of sodium

hypochlorite to the water in the

cisterns, for example to give a

calculated chlorine concentration of

50 ± 10 mg/L (ppm) in the water,

and leave the water to stand for one

hour. Whatever disinfection method

is used, the concentration should be

adjusted if necessary. The use of a

high dose ensures an adequate

residual concentration to allow

proper disinfection of the

downstream services. Each tap or

fitting should then be opened,

progressively away from the

cisterns, and water discharged until

the disinfectant is detected. Each

tap or fitting should then be closed,

and the cistern and pipes left

charged for a further hour. The

tap(s) furthermost from the cisterns

should be opened, and the level of

disinfectant in the water discharged

from the taps measured. If the

levels set are not achieved, the

disinfection process should be

repeated.

12MTechnical

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9. Temperature

Monitoring.

Check and record in logbook for

water hygiene the incoming feed to

the cistern storage at the ball valve

and remote from the ball valve (that

is farthest away from the incoming

supply within the cistern) once in

the summer and once in the winter.

Ensure temperature at ball valve is

<3°C of the incoming supply to the

building and similarly storage is

<3°C from ballvalve.

6M 10. Temperature

Monitoring.

Check and record in logbook for

water hygiene the incoming feed to

the cistern storage at the ball valve

and remote from the ball valve (that

is farthest away from the incoming

supply within the cistern) once in

the summer and once in the winter.

Ensure temperature at ball valve is

<3°C of the incoming supply to the

building and similarly storage is

<3°C from ball valve. Note

maximum temperatures recorded by

fixed max/min thermometers where

fitted

6MTechnical

10. Tanking. Ensure drains are clear, check

condition.

Check thoroughly for potential

leakage. Report to client.

12M 11. Tanking. Ensure drains are clear, check

condition.

Check thoroughly for potential

leakage. Report to client.

12MOther

11. Associated

pipework.

Check condition and rectify any

faults.

Examine for corrosion, leaks and

security of fittings and attachments.

12M 12. Associated

pipework.

Check condition and rectify any

faults.

Examine for corrosion, leaks and

security of fittings and attachments.

12MOther

12. Generally. Check that all items of equipment

comply with Legislation and

guidance (L8), HTM 04 (NHS),

WRAS the Water Supply (water

fittings) Regulations 1999

Report to client where remedial

action is required.

12M 13. Generally. Check that all items of equipment

comply with Legislation and

guidance (L8), HTM 04 (NHS),

WRAS the Water Supply (water

fittings) Regulations 1999

Report to client where remedial

action is required.

12MOther

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ICE STORAGE SYSTEMS56-03 56-03 ICE STORAGE SYSTEMS

Further guidance available from the National Health Service Document HTM 04 – Part B (Chapter 8

paragraph 8.8 to 8.13)

Further guidance available CIBSE TM 18

Air conditioning systems incorporating ice storage can need less general maintenance than

conventional systems. However, they normally have heat exchangers and some additional

instrumentation (flow meters etc.) and controls requiring maintenance. The tasks below should be

supplemented by those given from the specific manufacturer / supplier of the store and the complexity

of the particular system.

Care should be taken to prevent a control malfunction that would allow a total ‘freeze solid’ condition

to occur at the ice store. Primary to secondary heat exchangers should be thoroughly tested

especially in respect of low-temperature protection of secondary circuits.

Technical


1. Brine quality. Check Specific Gravity. If checks show continual need for

topping up brine Specific Gravity,

examine system for leaks.

3M Secondary coolant

circuit

Technical

2. System

pressurisation unit

(if used).

Check operation.6M 1. Glycol / Brine

concentration

Check percentage of glycol

concentration in circuit.

Correct as necessary. If checks

show continual need for topping up

Specific Gravity, examine system for

leaks.

1MTechnical

3. Tank shut off

unit (if fitted).

Check operation.6M 2. Valves Check operation of all isolating and

control valves

See Valves SFG 61 and 626MTechnical

3. Coolant flow

rates

Check and log flow rates and

pressure drops at appropriate loads

and conditions and check against

commissioning data

6MAdded

4. Circulating

pumps

Check operation of pumps. Take account of density of the

secondary coolant.

See Pumps SFG 45

6MAdded

5. Flow and return

temperatures

Check that the flow and return

temperatures across the ice store

are being achieved in both ice

charge and discharge modes.

6MAdded

6. Set points Check control set points for correct

values and operation.

3MAdded

Ice StoreAdded

1. Water level Check correct level of water in

storage container

6MAdded

2. Inventory device Check ice inventory device is

correctly calibrated and operating to

ensure correct glycol concentration

levels.

6MAdded

1. BMS Check that all temperatures,

pressures, flow rates etc., are being

received.

Check sensors for any not working.6MAdded

2. Insulation and

vapour barrier

Check all insulation is in place. Check to ensure the full record of

operating conditions over a period of

time is being saved.

6MAdded

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3. System

pressurisation unit

(if used).

Check operation. Should any pipework be removed

during and maintenance or repairs

ensure that it is reinstated paying

special attention to the quality of the

vapour sealing. The system will

need to be dried out prior to being

reinsulated to avoid sealing in

moisture which could corrode

pipework.

6MAdded

4. Tank shut off

unit (if fitted).

Check operation.6MAdded

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STORAGE TANKS - OIL56-05 56-05 STORAGE TANKS - OIL

The Control of Pollution (Oil Storage) (England) Regulations 2001 set minimum standards. They do

not change other legislation under which it is an offence to cause water pollution . Variations in local

conditions may mean more stringent standards are needed to prevent pollution.

If there is a spill, immediate action must be taken to stop the oil getting into any drains or

watercourses. Soak up the spilt oil with the contents of the spill kit in accordance with the risk

assessment. Don’t hose the spillage down or use any detergents to try to get rid of it. Notify the

Environment Agency by calling their Emergency Hotline on 0800 80 70 60.

If oil soaks into the ground, the soil soaked in oil should be removed, by a specialist company. Store

any materials that are soaked in oil in containers that won’t let the oil run away until it can be correctly

and legally disposed of.

In addition to the tasks there are daily and weekly operational tasks to be carried out including visual

checks of the oil tanks, pipework and bund. Please also see the section below [bund 3 monthly] which

refers to the removal of rain water. This must be done every time there has been heavy rainfall.

Refer to the Control of Substances Hazardous to Health (COSHH) Regulations. Staff to be Competent

and fully trained in COSHH. Risk Assessment / Method Statement requirements must be carried out

before the work starts and a method statement produced. Refer to www.hse.gov.uk for details.

Added


Bulk Oil Storage

[Heavy and

Medium Oils]

If there is a spill, immediate action

must be taken to stop the oil getting

into any drains or watercourses.

Soak up the spilt oil with the

contents of the spill kit in

accordance with the risk

assessment. Don’t hose the

spillage down or use any

detergents to try to get rid of it.

Notify the Environment Agency by

calling their Emergency Hotline on

0800 80 70 60.

Added

Outflow heater(s) Refer to the Control of Substances

Hazardous to Health (COSHH)

Regulations. Staff to be Competent

and fully trained in COSHH. Risk

Assessment / Method Statement

requirements must be carried out

before the work starts and a

method statement produced. Refer

to www.hse.gov.uk for details.

3MAdded

Oil log Check and log oil level. Log also

any inspections, any repair work on

the tanks and who’s done the

works.

3MAdded

Contents Gauge Dip tank to ensure gauge is

working.

3MAdded

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Valves and

pipework

Check valves are locked or have

there hand wheels removed [

vandalism / theft]. Pipework should

be checked for leaks, corrosion,

missing brackets etc. Check any

trace heating and insulation is in

place and working where

appropriate.

3MAdded

Valves and

pipework

Note settings of valves and take

through total travel, returning to

correct settings. Lock or remove

hand wheel as appropriate.

Pipework should be checked for

leaks, corrosion, missing brackets

etc.

12MAdded

Notices Check that the notice showing the

product type, tank capacity and,

where appropriate, tank number is

clearly visible – clean or replace as

necessary. Check all notices are

clearly visible warning that all

valves must be locked when not in

use.

3MAdded

Bund Bunds should be inspected

regularly for signs of damage, e.g.

missing bricks in walls and water in

the bund. Inspect closely where any

draw off / feed lines pass through

the bund wall to ensure it remains

fully sealed to retain oil.

Check that any trigger guns and

hoses are being kept within the

bund or the secure cabinet, which

should be locked shut when not in

use

Checked visually by the operator at

least weekly or after any heavy

rainfall.

Open bund - check the bund after

heavy rainfall. If there’s no rainwater

in the bund, it might not be sealed

properly and you should have it

inspected and repaired. Where rain

water has collected in the bund, it

will reduce the amount of oil it can

contain. To remove accumulated

rainwater, use a manually operated

pump or by bailing from the sump.

Any accumulated water, oil or debris

should be removed

and disposed of in line with waste

management legislation. In all cases

where wastes are removed, as the

waste producer you are obliged

under Waste management, the Duty

of Care, a code of practice (revised

1996) to describe the waste

accurately and dispose of it

properly.

Guidance on the disposal of

condensate and bund water. Joint

OFTEC/WaterUK/Environment

Agency/ SEPA publication.

3MAdded

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Bund A more detailed annual check by a

trained operator, e.g. in the OFTEC

registered scheme.

12MAdded

Overfill prevention

devices

Check that the device sounds the

alarm / shows the visual warning or

automatically stops the delivery –

whatever applies.

3MAdded

Fill points Check that the lockable fill cap and

chain are in place and work. Clean

the fill point drip tray.

3MAdded

Tank 60M Bulk Oil Storage [Heavy Oil]

Clean tank externally, derust and

paint, as found necessary. Place

No Smoking Signs, drain tank,

open manholes and vent tank.

Refer to Permit to Work and safe

Systems of Work before entering

tank, internally inspect, clean and

repair as found necessary. Report

condition before placing tank back

on-line. After maintenance

inspection, close all manholes and

covers, recharged tank and check

for leaks. Clean down exterior of

outdoor tanks and repaint with

bituminous paint. Inspect condition

of any fixed ladders, handrails and

catwalks. Check all fixings for

security

60MAdded

Daily (small) oil

storage

All tasks and frequencies are the

same as for Bulk Oil Storage

[Heavy and Medium Oils] above

without the task for out flow

heaters.

Added

1. Tank. Check condition and note any

corrosion.

Report to client.12M 1. Tank, bund

and surronding

area

Look for leakage and spillage from

the tank resulting from filling or

failure of tank soundness.

Report to client.3MTechnical

2. Filter. Replace if dirty and investigate

cause.

12M 2. Strainer

basket(s)

3MTechnical

3. Balloon Vent. Check condition of wire mesh.12M 3. Balloon Vent. In addition to the tasks there are

daily and weekly operational tasks

to be carried out including visual

checks of the oil tanks, pipework

and bund. Please also see the

section below [bund 3 monthly]

which refers to the removal of rain

water. This must be done every

time there has been heavy rainfall.

3MOther

4. Sludge valve. Check for leaks. If opened Waste Disposal

Regulations apply.

12M 4. Sludge valve /

cocks.

Check operation and freedom of

movement. Moving parts should be

lightly oiler or greased.

If opened Waste Disposal

Regulations apply.

3MTechnical

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56-06 UNDERGROUND OIL STORAGE TANKS

The Control of Pollution (Oil Storage) (England) Regulations 2001 and Groundwater Protection Code:

Petrol stations and other fuel dispensing facilities involving underground storage tanks set minimum

standards. They do not change other legislation under which it is an offence to cause water pollution .

Variations in local conditions may mean more stringent standards are needed to prevent pollution .

If there is a spill, immediate action must be taken to stop the oil getting into any drains or

watercourses. Soak up the spilt oil with the contents of the spill kit in accordance with the risk

assessment. Don’t hose the spillage down or use any detergents to try to get rid of it. Notify the

Environment Agency by calling their Emergency Hotline on 0800 80 70 60.

If oil soaks into the ground, the soil soaked in oil should be removed, by a specialist company. Store

any materials that are soaked in oil in containers that won’t let the oil run away until it can be correctly

and legally disposed of.

In addition to the tasks there are daily and weekly operational tasks to be carried out including visual

checks of the oil tanks, pipework .

Refer to the Control of Substances Hazardous to Health (COSHH) Regulations. Staff to be Competent

and fully trained in COSHH. Risk Assessment / Method Statement requirements must be carried out

before the work starts and a method statement produced. Refer to www.hse.gov.uk for details.

Added


1. Tank, bund

and surronding

area

Look for leakage and spillage from

the tank resulting from filling or

failure of tank soundness.

Report to client.3MAdded

2. Strainer

basket(s)

Remove and clean.3MAdded

3. Balloon Vent. Ensure that the vent is clear and

free from obstruction.

3MAdded

4. Sludge valve /

cocks.

Check operation and freedom of

movement. Moving parts should be

lightly oiler or greased.


Regulations apply.

3MAdded

5. Outflow

heater(s)

Ensure that all electrical

connections remain clean, tight and

dry.

Check for liquid leakage around

bolt-to-tank joint and element

sheaths.

When a drain connection is

provided loosen drain valve and

check for sludge build-up. If this is

excessive, isolate heater and drain

off quantity of sludge.


Regulations apply.

3MAdded

6. Oil log Check and log oil level. Log also

any inspections, any repair work on

the tanks and who’s done the

works.

3MAdded

7. Contents Gauge Dip tank to ensure gauge is working

and accurate

3MAdded

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8. Water detection Use a suitable paste on the dip

stick / line and check for water.

Remove water and increase

frequency of checks to ensure there

is no leakage into the tank.

3MAdded

9. Valves and

pipework

Check valves are locked or have

there hand wheels removed [

vandalism / theft]. Pipework should

be checked for leaks, corrosion,

missing brackets etc. Check any

trace heating and insulation is in

place and working where

appropriate.

3MAdded

10. Valves and

pipework

Note settings of valves and take

through total travel, returning to

correct settings. Lock or remove

hand wheel as appropriate.

Pipework should be checked for

leaks, corrosion, missing brackets

etc.

12MAdded

11. Notices Check that the notice showing the

product type, tank capacity and,

where appropriate, tank number is

clearly visible – clean or replace as

necessary. Check all notices are

clearly visible warning that all

valves must be locked when not in

use.

3MAdded

12. Overfill

prevention devices

Check that the device sounds the

alarm / shows the visual warning or

automatically stops the delivery –

whatever applies.

3MAdded

13. Fill points Check that the lockable fill cap and

chain are in place and work. Clean

the fill point drip tray.

3MAdded

14. Leakage

detection

Check that the system is operating

correctly as per manufacturers

guidelines.

In addition to this tasks there are

daily and weekly operational tasks

to be carried out to check leakage

detection.

3MAdded

15. Cathodic

protection devices

Added

i) Sacrificial anode Check condition and record results This must be checked within 6

months of any new installation or

repair to the sacrificial anode

system. The results of the last two

tests must be retained on site.

36MAdded

ii) Impressed

current

Check condition and record results The results of the last three tests

must be retained on site.

2MAdded

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16. Soil condition

checks

Check soil conditions in terms of

moisture content, electrical

conductivity, pH, sulphide

concentration and chloride

concentration.

Usually the corrosion of buried steel

occurs as a result of electrochemical

reactions with constituents of the

enclosing soils. In order to assess

the risk of corrosion failure, it is

necessary to ascertain soil

conditions such as moisture content,

electrical conductivity, pH, sulphide

concentration and chloride

concentration. This data, once

collected, can be analysed using a

standard method to determine the

probability of a leak caused by

corrosion, both at present and in the

future. Assessment of corrosion

probability will help to decide if

urgent action is required, e.g. the

fitting of cathodic protection, tank

lining or the replacement of a tank.

12MAdded

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56-07 STORAGE SILO - wood chip / pellets

There are several hazards in entering and working in a silo. The main hazards include difficult access

and egress, which makes entrapment, escape and rescue more problematic; being engulfed in a free

flowing material if the chips/pellets have blocked and

bridged; the accumulation of vapours, gases or fumes; and the lack of ventilation. Some of these

hazards may be introduced into the silo by the nature of the maintenance work (e.g. welding work

or cleaning work with solvents) or by incoming services.

Added


1. Silos and

storage rooms

Chip silos and storage rooms

should be cleaned out at the end of

each heating season, to avoid

accumulation of dust, bacteria and

fungi.

Chip reception pits should be

equipped with a ladder (set

into the wall) to facilitate entry and

egress.

12MAdded

2. Burn back

control

Check the burn back control device

is in place and that the sensor / wax

seal is operational. Check that the

water supply pressure is correct

[normally in excess of 1 bar].

12MAdded

3. Rubber mat In case of bulk-blown pellet

deliveries - check that the rubber

mat is in place and that there is at

least a 20mm air gap from a wall

opposite the inlet to the store.

12MAdded

Page 522 of 614

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Change

56-08 STORAGE SILO - COAL

The burning of coal is a complex operation involving the storage, handling of solid material, together

with the handling. Coal is abrasive and the wear and tear on mechanical plant considerable, hence

regular maintenance is vital to ensure continuous working and a clean environment.

A risk assessment and method statement must be undertaken before entering any confined space

such as a hopper / silo to ensure that there is adequate ventilation and an absence of any fumes or

flue gases.

Added


1. Status. Empty and check internal and

external coatings.

If there are signs of deterioration

consult the manufacturer.

12MAdded

Page 523 of 614

SWIMMING POOLS

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There are two major aspects of swimming pool maintenance, water cleanliness, quality and

winterisation.

The maintaining of a high standard of water cleanliness and quality, calls for daily monitoring and

treatment which must be part of the daily routine of the pool attendant and will cover filters, water

treatment and general cleanliness. In addition regular maintenance of the equipment is necessary and

except in large installations this would normally be carried out by the maintenance contractor at

intervals agreed with the client.

For outdoor pools which are not used in winter whilst it is not normal practice to empty the pool the

specific maintenance procedures should include provision for ensuring that the plant is secure from

frost damage by draining down pumps, pipelines and associated tanks and where appropriate the

pool valves isolated.

This section also covers whirlpool and spa baths, steam rooms, e.g. saunas and hydrotherapy pools.

All this equipment uses hot water and in the maintenance procedures account must therefore be

taken of the dangers of Legionella, see HSE ACOP L8,2001.

There are two major aspects of swimming pool maintenance, water cleanliness / quality and

winterisation.

The maintaining of a high standard of water cleanliness and quality, calls for daily monitoring and

treatment which must be part of the daily routine of the pool attendant and will cover filters, water

treatment and general cleanliness. In addition regular maintenance of the equipment is necessary and

except in large installations this would normally be carried out by the maintenance service provider at

intervals agreed with the client. Maintenance procedures must take account of the dangers of

Legionella, see HSE ACOP L8,2000 (www.hse.gov.uk).

For outdoor pools which are not used in winter whilst it is not normal practice to empty the pool the

specific maintenance procedures should include provision for ensuring that the plant is secure from

frost damage by draining down pumps, pipelines and associated tanks and where appropriate the

pool valves isolated.

This section does not cover whirlpool and spa baths, steam rooms, e.g. saunas and hydrotherapy

pools these are dealt with in Whirlpools - hydrontherapy SFG 66.

Discharge of Water

In England and Wales discharge to sewers requires the consent of the local water service company ;

discharge to a water course has to be authorized by the regional office of the Environment Agency . In

Scotland the relevant authorities are the local water authority and Environment Protection Agency

respectively; in N. Ireland, the Department of the Environment.

These authorities may have specific requirements about the rate and quality of discharges from

backwashing, dilution, pool emptying etc. Such authorities should be consulted about the operation of

a pool and any proposed changes to it.

Backwash water may need dechlorination if it is to be discharged to a surface water drain

Technical

Page 525 of 614

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SWIMMING POOLS57-02 57-02 SWIMMING POOLS

The main periods for maintaining outdoor swimming pools are in early autumn when the system is

shut down for the winter and the equipment and pool are prepared for the winter and in the late spring

when the pool is made ready for the new season. For indoor pools maintenance should be

programmed for times of minimum use. If fitted constructed with membrane liner care should be taken

to avoid perforation with sharp edges of equipment. Maintenance of water quality is a daily operation

usually carried out either automatically or manually by the pool attendant. (See WATER

TREATMENT).

The main periods for maintaining outdoor swimming pools are in early autumn when the system is

shut down for the winter and the equipment and pool are prepared for the winter and in the late spring

when the pool is made ready for the new season. For indoor pools maintenance should be

programmed for times of minimum use. If constructed with membrane liner ,care should be taken to

avoid perforation with sharp edges of equipment. Maintenance of water quality is a daily operation

usually carried out either automatically or manually by the pool attendant. See Water treatment SFG

65. It is also assumed that cleaning of the pool areas to comply with PAS 39:2003 will be undertaken

by the clients operational staff

Technical


1. Shut down. Isolate from electrical supply by

switching off and withdrawing

fuses.

Ensure that water supply is also

turned off.

12M 3. Shut down. If Required, Isolate from electrical

supply by switching off and

withdrawing fuses.

Ensure that water supply is also

turned off.

6MOther

2. Controls. Check settings and action.12M 4a. Controls. Check settings and action.6MOther

3. Pool cover(s). Check for tears and soundness.

Check condition and security of

anchor bolts.

12M 5. Pool cover(s). Check for tears and soundness.

Check condition and security of

anchor bolts. The underside of pool

covers and moveable floors should

be checked regularly and cleaned

as necessary

6MOther

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Water Quality

Testing

Carry out routine testing of the

water quality. Tests should include:

water clarity

disinfectant level

pH

water temperature

air temperature

The manual monitoring and

measurement of the chemical state

of the pool water should be

performed using colorimetric

comparison kits (comparator or

spectrophotometer) or commercially

available test kits using test tablets.

The accuracy of test kits should be

maintained by:

a) keeping them scrupulously clean

(including rinsing glassware

components with deionized water to

ensure that all traces of test

reagents from previous uses are

removed);

b) using separate cells for pH and

disinfectant testing;

c) not exceeding the shelf life of the

test reagents;

d) following storage instructions;

e) using only the test kit

manufacturer’s specified test

tablets;

f) diluting and testing a second

sample for disinfectant residuals if

the first gives a result at the top or

the bottom of the kit’s range;

g) using a test kit with the applicable

range for the water under test; and

h) being aware of the potential false

readings that can arise from things

like high calcium hardness and

contamination with pool cleaning

chemicals.

Where free chlorine levels are not

monitored and controlled

automatically by the water treatment

plant, manual testing should be

carried out, using commercially

available test kits and the

appropriate tablets.

These tests should be undertaken:

a) before the pool opens;

b) every 2 h during opening hours;

and

c) after it closes.

Even when free chlorine levels are

monitored and controlled by

automatic systems, chlorine levels

should be tested manually at least

three times daily at the start,

midway and at the end of each day.

The tests should monitor both free

1DAdded

Page 527 of 614

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chlorine and combined chlorine

residuals.

Pool water samples for analysis

should be taken at a depth of 200

mm to 400 mm, from a part of the

pool that has been found to be

representative of the general

concentration.

Water Quality

Testing

Carry out routine testing of the

water quality. Tests should include:

alkalinity,

cyanuric acid

See Notes above1WAdded

2. Suction Filters. Clean Filters1DAdded

1. Transfer

Channels

If applicable, the deck-level

transfer channels are be drained a

minimum of once a month. They

should be flushed out with a

disinfecting solution suitable for the

task, for example 10 mg/l

chlorinated water, which can be

returned to the balance tank. The

undersides of transfer channel

grilles should be cleaned.

1MAdded

2. Balance Tanks Balance tanks should be drained at

least twice per year. Debris should

be removed and inner surfaces

brushed and flushed down with a

disinfecting solution, for example 10

mg/l chlorinated water, which can

be returned to the circulation

system via the filters. For safety,

individuals should not enter balance

tanks on their own

6MAdded

4b. Controls Re-calibrate automatic monitoring

equipment. Check all control

indicator lamps and alarms.

1MAdded

6. Suspended

ceilings

In the case of an indoor pool having

a suspended ceiling the wire

hangers holding the ceiling frame to

the slab should be checked by a

structural engineer due to the highly

corrosion nature of the atmosphere

and the possibility of the ceiling

collapsing.

6MAdded

7. Log Book Check log book for any reported

defects and attend as required. Any

works carried out should be clearly

recorded in accordance with the

operating code of practice.

This task is in addition to the daily

check carried out as part of any

operational procedure.

1MAdded

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8. Chlorine gas

detectors

Check chlorine gas detectors in the

plantroom / chemical store.

6MAdded

9. Chemical

dosing

Check and clean the chemical

control system including all dosing

and monitoring equipment. In

addition any specialist items like

ozonators and ultraviolet lamps.

Although the frequency has been

set at 6 Months, the DFE guidance

note Guide 2, Managing Schol

Facilities requires a minimum of 4

visits per year

6MAdded

10. ElectricalAdded

Zones 0 & 1 Ensure notices on all outlets and

control devices are in place.

12MAdded

Supplementary

bonding

Check that all extraneous

conductive parts in zones 0, 1 and

2 are connected by supplementary

bonding conductors to the

protective conductors of exposed

conductive parts in these zones.

12MAdded

Added

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SWIMMING POOLS - FILTERS57-03 57-03 SWIMMING POOLS - FILTERS

Filtration plant. The filtration plant of a pool is designed to remove water from the pool, filter it,

disinfect it and return it to the pool in a sterile condition. The main types of pool filters are:

a) Conventional rate pressure sand filtration

b) Medium rate pressure sand filtration

c) High rate pressure sand filtration

d) Pre-coat cartridge (pressure and vacuum)

e) Disposable cartridge or glass fibre mat filtration

Filtration plant. The filtration plant of a pool is designed to remove water from the pool, filter it,

disinfect it and return it to the pool in a sterile condition. Effective filtration should ensure that water

clarity is good enough to allow unclouded or clear sight of the

bottom of the pool at the deep end.

The main types of pool filters are:

a) Conventional rate pressure sand filtration

b) Medium rate pressure sand filtration


d) Pre-coat cartridge (pressure and vacuum)

e) Disposable cartridge or glass fibre mat filtration

Effective filtration should ensure that water clarity is good enough to allow unclouded or clear sight of

the bottom of the pool at the deep end.

The water turbidity should not exceed 0.5 NTU (nephelometric turbidity units).

Other


1. Backwashing Carry out backwashing of main

filters and discharge the back wash

water to waste. Backwash flow

should be fast enough to fluidise

the sand bed and should have a

speed of at least 30 m/h.

Fluidisation of the bed should be

checked visually if possible, through

a viewing window where provided.

Backwashing should continue at

least as long as recommended by

the manufacturer, but certainly until

the backwash water is clear.

Filters should be backwashed at

least once a week and whenever

the pressure loss across the sand

bed reaches the level specified by

the filter manufacturer.

Filters should be backwashed if the

water circulation has been stopped

(because of a failure or for

maintenance). Backwashing is best

done at the end of the working day.

Air scouring prior to the

backwashing at a speed of

approximately 32 m/h can aid the

backwashing process.

If a filter is being backwashed while

other filters are still in service, flow

to the filter should start and stop

slowly over a 15 second to 20

second period to avoid rapid flow

rate change in the in-service filters.

1WAdded

5. Filter bed Inspect the filter and the top of the

sand bed. Check for signs of

corrosion, problems with the

under-drains and problems with the

filter medium e.g. mud balling,

fissures, uneven bed.

12MAdded

1. Inlet strainer. Check condition and clean. More frequent cleaning by the

operator may be necessary if the

inlet flow rate falls below the design

level. (May be shown by increased

suction pressure).

12M 2. Inlet strainer. Check condition and clean. More frequent cleaning by the




suction pressure).

12MOther

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2. Chemical

cleaning of filter

bed material.

Check clean `running' pressure, if

high, may indicate fouling of filter

medium.

Refer to manufacturer's handbook

for instructions and type of

chemicals to be used.

12M 3. Chemical

cleaning of filter

bed material.

Check clean `running` pressure, if


medium.

Refer to manufacturer`s handbook



12MOther

3. Rate of flow

indicator.

Clean and check operation. The accuracy of the flow meter

should be within 5%.

12M 4. Rate of flow

indicator.



12MOther

Pre-coat filtration

1. Inlet strainer.

Check condition and clean. More frequent cleaning by the




suction pressure).

12M Pre-coat filtration

1. Inlet strainer.





suction pressure).

12MOther

2. Filter

elements.

Clean off any coating material and

check condition of support

elements.


client.

12M 2. Filter

elements.



elements.

The frequency of this task can be

increased where Coagulants

(sometimes called flocculants) are

not used to enhance the removal of

dissolved, colloidal or suspended

material.

1MTechnical

3. Pipework. Clean off any deposits or sludges.12M 3. Pipework. Clean off any deposits or sludge`s.12MOther

Cartridge type

filters 1. Inlet

strainer.





suction pressure).

12M Cartridge type

filters 1. Inlet

strainer.





suction pressure).

1MTechnical

2. Seals. Check condition of seals on

cartridge holders. Replace if

necessary.

12M 2. Seals. Check condition of seals on


necessary.

1MTechnical

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SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.57-04 57-04 SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.


3. Heating

equipment - Oil -

Solar

-Gas

Carry out maintenance procedures

appropriate to the type of heating

plant as detailed in relevant

sections.

Maintenance of heating plant, other

than routine, is best carried out

before the heating season starts.

6M 3. Heating

equipment - Oil -

Solar

-Gas - Heat Pump




sections. Ensure that the pool

temperature is maintained in

accordance with PAS 39:2003

Table 3. The air temperature should

be no more than 1oC above the

pool temperature. For further

guidance on Maintenance see

Boilers - heat generators SFG 05,

Solar panels SFG 53, and Heat

exchangers SFG 29.








visits per year.

6MTechnical

Hot water

temperature (at

outlet of post swim

showers).


ACOP L8, 2000 requirements. Hot

water supplied to the showers

should be piped at no less than 50

°C and mixed to (41 ± 2) °C.





to be put in hand.

1MAdded

Indoor air

temperatures and

RH

Manually check the pool hall air

temperatures and Relative Humidity

levels

The pool hall air temperatures

should be no more than 1 °C above

that of the water temperature.

Air temperatures over 30 °C should

be avoided.

Relative humidity should be

maintained at a level of (60 ± 10) %

throughout the pool hall area.

1WAdded

3. Pump Check for leaks and corrosion,

tighten gland if required. Check

electrical connections for tightness

and signs of corrosion.

See also Pumps SFG 45.





visits per year

12MAdded

4. Ventilation Carry out maintenance procedures

on the ventilation plant serving the

pool and changing areas. For

further Guidance on Maintenance

see Air handling units SFG 03,

Ducting SFG 16 and Fans SFG 20.

The Relative humidity should be

maintained at a level of (60 ± 10) %

throughout the pool hall area. It is

understood that manufacturers of

AHU`s and ductwork specified for

swimming pools will coat internal

surfaces to protect from Chlorine

attack. Therefore standard

maintenance frequencies

recommended in SFG 03, 16 and

20 can be used.

3MAdded

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57-04 SWIMMING POOLS - PIPEWORK, PUMPS, HEATING etc.

Once a pool is winterised then the level of regular maintenance required is very much less than during

the season. There are no hard and fast rules governing the actual date of winterising; however the

lower ambient temperature becomes the more expensive the heating becomes.

The Pool must not be emptied, without professional advice, as hydrostatic pressures can force a

concrete structure out of the ground and ground water can lift and displace liners.

All floating covers should be removed from the pool, cleaned and carefully dried and stored safely

away from vermin. Slatted covers should be cleaned and rolled away for the winter. The fitting of a

proper winter cover will help keep the majority of debris and sunlight out of the pool.

Winterising does not mean that the algae will stop growing, therefore there will be a requirement to

treat the water until the water temperature

drops to about 7°C.

Remove, clean and store all pool-side equipment and summer covers etc. Check all filtration, heating

and cleaning equipment and report on its condition. Remove and store pool cleaner if fitted. De-leaf

and clean the pool.

Check the chemical values and adjust including a shock dose. A number of chemicals which are long

lasting are available for winterisation. However the variance of winter weather and temperature affects

the longevity of these products and occasional testing is recommended

Added


Option 1

Winterisation

Lower the level of the pool water* to

approximately 30 cms below the

skimmers as a frost precaution and

plug

and empty out the skimmer. Store

the pumps in a warm environment.

Isolate all electrics and drain all

equipment such as pumps,

filters, heaters etc. Leave the pool

area and plant room in a tidy state.

1YAdded

Water Testing Check the water condition regularly

and dose if required.

This can be easily done by lifting a

corner of the cover.

Chemicals that dissolve quickly in

the summer will be slower

reacting in the winter, so pre

dissolving them is essential.

1MAdded

Option 2

Winterisation

Set the filter pump time clock

control to allow the pump to run for

one hour per day and set a frost

thermostat to 2oC. Install a bypass

around the heater and drain the

heater, electrically disconnect, or

switch off other

equipment..

1YAdded

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Water Testing Check the water condition regularly

and dose if required.

This can be easily done by lifting a

corner of the cover.

Chemicals that dissolve quickly in

the summer will be slower

reacting in the winter, so pre

dissolving them is essential.

1MAdded

Filters backwash the filter, once every 2

months, or if pool water level

increases

from rainfall.

2MAdded

Re-commissioning Remove the winter cover from the

pool, clean it off, dry and fold it,

then store away. . Store the cover

away from vermin.

• Clean the coping stones and

surround paving to remove any

mould or algae growth.

• Re-fit all the pool side equipment

such as ladders, diving boards etc.

• If necessary re-assemble all the

filtration and heating equipment in

the plant room

• Start the equipment and

thoroughly test it. Heaters should

not be left running unless specific

instructions have been provided.

• Set all time clocks forcorrect

running hours.

• Check all valves for freedom of

operation and ease if necessary.

• De-leaf pool and vacuum or set

the pool cleaner in operation.

• Check and adjust the chemical

values.

• Generally tidy and clean the pool

area and plant room.

Once the pool has been

recommissioned,

run the filter continually for the first

5 days, backwashing daily, to

thoroughly clean the water.

1YAdded

Page 534 of 614

SWITCHES

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ON/OFF SWITCHING DEVICES58-01 58-01 ON/OFF SWITCHING DEVICES


1. Condition Clean and check operation.12MAdded

Vane operated

flow switches

Added

Differential

pressure switches

1. Condition.

Clean and check operation.12M Differential

pressure switches

.

Other

4. Calibration. Check against standard.12M Deleted

Vane operated

flow switches 1.

Condition.

Clean and check operation.12M 1. Condition. Clean and check operation.12MOther

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CONTROL RELAYS58-02 58-02 CONTROL RELAYS


1. General

maintenance.

Carry out as per instructions given

in CONTROL PANELS.

12M 1. General

maintenance.

Carry out as per instructions given

in Control panels SFG 14.

12MOther

Page 537 of 614

TERMINAL UNITS

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TERMINAL UNITS VAV - self powered59-01 59-01 TERMINAL UNITS VAV - self powered


2. Unit filter. Check condition and change if

necessary.

If unit filter is very dirty, check

condition of main filter.

12M 3. Unit filter. Check condition and clean or

change if necessary.

If unit filter is very dirty, check

condition of main filter.

3MTechnical

3. Main filter. Check condition. In a dirty environment it may be

necessary to clean/change main

filter more frequently.

3M Deleted

2. Bellows Where fitted, check condition of

bellows and replace as necessary

6MAdded

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The term Terminal Units covers those items of equipment relating to the ingress of ventilating or

conditioned air into the working environment. Operationally their effectiveness may be impaired by the

build up of dust and related deposits whilst visually dirt will arise from cigarette smoke and dirt in the

atmosphere. In a dirty environment it may be necessary to increase the frequency of maintenance

above that recommended in this specification. Detailed maintenance of the associated controls is

covered in the relevant section.


conditioned air into the working environment. Operationally their effectiveness may be impaired by

the build up of dust and related deposits whilst visually dirt will arise from the atmosphere. In a dirty

environment it may be necessary to increase the frequency of maintenance above that recommended

in this specification. Detailed maintenance of the associated controls is covered in the Controls

SFG14 section.

Technical

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TERMINAL UNITS VAV - fan powered59-02 59-02 TERMINAL UNITS VAV - fan powered


5. Reheaters Check operation and carry out

routine maintenance

For further guidance on maintaining

the reheaters see Heat exchangers

SFG 29-01 and 29-02.

6MAdded

1. Fan motor. Grease or oil bearings.6M 1. Fan motor. Grease or oil bearings. For further guidance on maintaining

fan motors see Motors SFG 39-01.

6MTechnical

2. Dampers. Check operation and lubricate

linkages if necessary.

6M 2. Dampers. Check operation and lubricate

linkages if necessary.

For further guidance on maintaining

damper actuators see Actuators

SFG 01.

6MTechnical

3. LPH and CW

coils.

Check operation and clean.6M 3. LPHW and

CW coils.

Check operation and clean. Comb

any fin damaged areas.

6MTechnical

4. Controls. Check operation. Note:- Calibration,

Interrogation, Control adjustment.

6M 4. Controls. Check operation. Calibration, Interrogation, Control

adjustment. For further guidance on

maintaining controls see Control

panels & controllers SFG 14.

6MTechnical

Page 541 of 614

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above that recommended in this specification. For detailed maintenance of associated equipment see

CONTROLS.






SFG14 section.

Technical

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TERMINAL UNITS VAV - pneumatic powered59-03 59-03 TERMINAL UNITS VAV - pneumatic powered


5. Actuator. If visible, check for dirt, lightly oil

mechanism as required.

12M 5. Actuator. If visible, check for dirt, lightly oil

mechanism as described in

Actuators SFG 01-01 - 01-08

12MOther

7. Filter. Clean or replace as necessary. Frequency of cleaning will depend

upon the environment in which the

unit operates.

6M 7. Filter. Clean or replace as necessary. Frequency of cleaning will depend

upon the environment in which the

unit operates.

3MTechnical

Page 543 of 614

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CONTROLS.






SFG14 section.

Technical

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TERMINAL UNITS - Constant volume including mixing59-04 59-04 TERMINAL UNITS - Constant volume including mixing


2. Pneumatic

thermostats.

Check operation by moving set

point. Restore to original setting.


relevant section.

12M 2. Pneumatic

thermostats.

Check operation by moving set


12MTechnical

3. Control

dampers.

Check operation. For high velocity

mixing box change over dampers.

Check seals.

For more information on damper

maintenance see DUCTING

GENERAL .

12M 3. Control

dampers.

Check operation. For high velocity

mixing box change over dampers.

Check seals.

For more information on damper

maintenance see Ducting general

SFG16.

12MOther

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CONTROLS.






SFG14 section.

Technical

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TERMINAL UNITS - INDUCTION UNITS59-05 59-05 TERMINAL UNITS - INDUCTION UNITS


5. Damper and/or

pneumatic valves.

Check correct functioning and

rectify any defects.

6M 5. Damper and/or

pneumatic valves.

Check correct functioning and

rectify any defects.

For further guidance see Actuators -

pnuematic actuators SFG 01-04.

6MOther

6. Chilled

water/LPHW

control valves.

Check functioning. For detailed maintenance see

VALVES.

6M 6. Chilled

water/LPHW

control valves.


Valves SFG 62-01 - 62-07.

6MOther

7. Control

thermostats.

Check operation. Setting should be 19ºC heating and

24ºC cooling. For detailed

maintenance see relevant section.

6M 7. Control

thermostats.

Check operation. Setting should be 19oC heating and

24oC cooling. For detailed

maintenance see relevant section

Switches SFG 58-01.

6MTechnical

8. Isolation

valves.

Check for leaks and rectify as

necessary.

6M 8. Isolation

valves.

Check for leaks and rectify as

necessary.


Valves SFG 62-01 - 62-07.

6MOther

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CONTROLS.






SFG14 section.

Technical

Page 548 of 614

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TERMINAL UNITS - FAN COIL59-06 59-06 TERMINAL UNITS - FAN COIL


9. Strainers Inspect and clean strainers as

necessary.

Report any build up of sludge/filing

to the client.

12MAdded

10. Chilled

water/LPHW

control valves.


Valves SFG 62-01 to 62-07.

6MAdded

11. Thermostats. Check operation by moving set



Switches SFG 58-01.

12MAdded

1. Status. Switch off and isolate. Electrical isolation should be carried

out in accordance with HSAWA

recommendations. Where units are

ceiling mounted, cover any office

machinery/equipment situated below

unit being serviced.

6M 1. Status. Switch off and isolate. Electrical isolation should be carried

out in accordance with HSE

Guidance document HSG85:2007.

Where units are ceiling mounted,

cover any office

machinery/equipment situated

below unit being serviced.

6MTechnical

2. Coil block. Vent air from cooler and heating

coils (if AAV not fitted).

3M Deleted

3. Condensate

drain connection.

Check connection is clear.6M 2. Condensate

drain connection

and pump

Check connection is clear. Ensure

condensate lift pump is operational

and able to discharge condensate

to the drainage pipework.

The check should also ensure that

the condensate drainage pipework

has the correct fall to allow water to

flow to the drainage stack

6MTechnical

4. Permanent

filters.

Clean and refit, ensuring proper

location.

See FILTERS regarding safety

instructions.

6M 3. Permanent

filters.

Clean and refit, ensuring proper

location.

See Filters SFG 21-02 regarding

safety instructions.

6MTechnical

5. Disposable

type filters.

Replace ensuring proper location. See FILTERS with regard to safety

and disposal procedures.

6M 4. Disposable

type filters.

Replace ensuring proper location. See Filters SFG 21-02 with regard

to safety and disposal procedures.

6MTechnical

6. Test unit. Restore power supply and run unit.

Check airflow is normal at correct

speed setting.

6M 5. Test unit. Restore power supply and run unit.

Check airflow is normal at correct

speed setting.

6MTechnical

7. Casing. Clean. Where units are above false ceilings

ensure that tiles are not left in a

stained condition.

6M 6. Casing. Clean. Where units are above false ceilings

ensure that tiles are not left in a

stained condition.

6MOther

8. Ductwork

flexible couplings

(if fitted).

Check condition.12M 7. Ductwork

flexible couplings

(if fitted).

Check condition. Repair/refix any

ductwork to the spigots as

necessary.

12MOther

9. Grilles and

diffusers.

Clean using vacuum or alternatively

remove and clean.


damage to diffuser ceiling lights or

ceiling.

6M 8. Grilles and

diffusers.

Clean using vacuum or alternatively

remove and clean.


damage to diffuser ceiling lights or

ceiling.

12MOther

Page 549 of 614

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Change

TERMINAL UNITS VRV SYSTEMS59-07 59-07 TERMINAL UNITS VRV SYSTEMS





Added


2. Coils. Clean and remove any debris.3M 2. Coils. Clean and remove any debris.

Comb any damaged areas of fin.

3MTechnical

3. PCBs. Check for damage.3M 5. PCBs. Check for damage.3MOther

4. Electrical

Components.

Check condition.3M 6. Electrical

Components.


5. Sensors. Check for contact and correct

location.

3M 7. Sensors. Check for contact and correct

location.

3MOther

6. Running

currents and

voltage.

Check and record.3M 8. Running

currents and

voltage.

Check and record.3MOther

7. System neutral

and earth

connections.

Check.3M 9. System neutral

and earth

connections.

Check power supply to unit and

neutral and earth connections.

Record.

3MTechnical

Indoor Unit 8.

Hand Controllers.

Check function. Run units on heating and cooling

cycles if heat pumps

3M Indoor Unit

10. Hand

Controllers.

Check function. Run units on heating and cooling

cycles if heat pumps. Replace

batteries on remote control units as

necessary

3MTechnical

9. Air Filter and

indoor coils.

Clean. Air Filters may initially require

monthly cleaning dependant on

location.

3M 11. Air Filter and

indoor coils.

Clean. Air Filters may initially require

monthly cleaning dependant on

location. For further guidance see

Filters SFG 21-02.

3MOther

10. Drain Lines. Check for free running3M 12. Drain Lines. Check for free running3MOther

11. Power supply. Check and record.3M Deleted

12. Electrical and

Data Cable

connections.

Check condition.3M 13. Electrical and

Data Cable

connections.


13. Change over

valves and

refrigerant control

devices.

Check action. If a shortage of refrigerant is

suspected all should be removed,

any leaks rectified and the

refrigerant change weighed in after

calculation change using the

Manufacturers literature. This

work must only be carried out by

a contractor registered with

REFCOM , or other mandatory

scheme provider.

3M 14. Change over

valves and

refrigerant control

devices.

Check action. If a shortage of refrigerant is

suspected all should be removed,

any leaks rectified and the

refrigerant change weighed in after

calculation change using the

Manufacturers literature. This work

must only be carried out by a

service provider registered with an

authorised scheme provider.

3MTechnical

Page 550 of 614

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Reason For

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3a. Leaks - Oil Check for oil leaks. Any leak of

refrigerant should be dealt with

immediately.

6MAdded

4. Compressors Carry out Service of the

compressor

For further guidance see

Compressors - refrigeration SFG

12-01.

6MAdded

3 . Leaks -

Refrigerant

Check refrigerant Charge,










measuring methods.



attendants.

Any removed refrigerant must be


atmosphere.






Added

A) Normal

systems:

<3 kg




0MAdded




12MAdded




6MAdded




3MAdded

E) Hermetically

sealed systems:

<6 kg




0MAdded




12MAdded




6MAdded




3MAdded

Page 551 of 614

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Change







CONTROLS.

VRV Systems are very specialist and should not be treated as a standard split system. They are set

up on commissioning and the set points should not be disturbed.






SFG14 section.

VRV Systems are very specialist and should not be treated as a standard split system.

They are set up on commissioning and the set points should not be disturbed.

Technical

Page 552 of 614

VACUUM SYSTEMS

Page 553 of 614

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Reason For

Change

VACUUM SYSTEMS - general60-01 60-01 VACUUM SYSTEMS - general

In addition to routine maintenance, examinations of some pressure vessels are required under the

Pressure Systems Safety Regulations 2000 - see relevant section 40-08.

Maintenance should be carried out by only competent persons.

Added


1. Motors. Follow procedure given for

MOTORS.

12M 1. Motors. Follow procedure given for Motors

SFG 39-01.

12MOther

Air systems -

cleaning 2. Fans.

Follow procedure given for FANS. As used in centralised vacuum

cleaning systems.

12M Air systems -

cleaning

2. Fans.

Follow procedure given for Fans

SFG 20.

As used in centralised vacuum

cleaning systems.

12MOther

5. Filters. Check condition and change as

necessary. See FILTERS.

12M 5. Filters. Check condition and change as

necessary. See Filters SFG 21-02.

12MOther

Liquid systems 7.

Pumps (liquid

systems).

Follow procedure given for PUMPS. As used for swimming and

hydrotherapy pools.

12M Liquid systems

7. Pumps.

Follow procedure given for Pumps

SFG 45.

As used for swimming and

hydrotherapy pools.

12MOther

9. Filters. Check condition and change as

necessary.

12M 9. Filters. Check condition and change as

necessary. See Filters SFG 21.

12MOther

Page 554 of 614

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VACUUM TUBES - cash handling60-02 60-02 VACUUM TUBES - cash handling

In addition to routine maintenance, examinations of some pressure vessels are required under the

Pressure Systems Safety Regulations 2000 - see relevant section 40-08.

Maintenance should be carried out by only competent persons.

Added


d) contactors, Check operation and condition. For more detailed information on the

maintenance of contactors see

POWER SUPPLIES P.D.U.

12M d) contactors, Check operation and condition. For more detailed information on the

maintenance of contactors see

Power supplies (P.D.U) SFG 44-05.

12MOther

e) earth continuity. Check For more detailed information on the

maintenance of earthing electrical

equipment see POWER SUPPLIES

EARTHING.

12M e) earth continuity. Check For more detailed information on the

maintenance of earthing electrical

equipment see Power supplies

earthing SFG 44-06.

12MTechnical

Controller 5. a)

running time of

capsule b) relay

on capsule.

Check Check condition.12M Controller 4. a)

running time of

capsule b) relay

on capsule.


c) system filters (if

fitted), d) carrier

(capsule(s)), e)

carrier velcro and

lids.

Check pull. Check condition.6M c) system filters (if

fitted), d) carrier

(capsule(s)), e)

carrier Velcro and

lids.

Check pull. Check condition. For more detailed information on the

maintenance of system filters see

Filters SFG 21-02.

6MTechnical

Page 555 of 614

VALVES

Page 556 of 614

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VALVES61-01 61-01 VALVES

When opening valves (especially steam valves etc.) they must be done in such a way as to avoid the

chances of `water hammer` occurring.

Added


2. Inspection Strip down, overhaul and then

rebuild to comply with the

Competent Persons requirements

under the Pressure Regulation and

the written scheme of examination.

The Competent Person may require

additional testing on completion of

the rebuild

12MAdded

1. Operational

status.

Check, rotate handwheel

sufficiently to indicate that wedge is

not seized in closed position nor

jammed in open position. If

normally open, close valve and

reopen.

Action depends upon whether valve

is normally closed or normally open.

If valve is normally open, check

closure performance in the event

that corrosive deposits prevent

wedge seating.

3M 1. Operational

status.

Check, rotate handwheel

sufficiently to indicate that wedge is

not seized in closed position nor

jammed in open position. If

normally open, close valve and

reopen. When fully open, close


not jam.

Action depends upon whether valve

is normally closed or normally open.

If valve is normally open, check

closure performance in the event

that corrosive deposits prevent

wedge seating.

3MTechnical

2. Gland leakage. Check, within first week slightly

tighten gland nuts. If after a period

leakage still occurs replace gland.



one week. Early signs of slight leaks

are due to 'bedding in' or drying out

and are usually cured by tightening

of gland nuts. Continuous leakage

can lead to erosion or corrosion of

the valve stem.

3M 2. Gland leakage. Ensure correct packing material is










stem.

3MTechnical

1. Operational

status.

Check by rotating handwheel


movement.

3M 1. Operational

status.

Check by rotating handwheel




not jam.

3MOther

2. Gland leakage. Check within first week, slightly


leakage still occurs, replace gland.








the valve stem.

3M 2. Gland leakage. Ensure correct packing material is










stem.

3MTechnical

2. Stem leakage. If evidence of leakage, inject

correct compound simultaneously

rotating plug.

After installation or overhaul check

daily for one week and then at six

monthly intervals.

3M 2. Stem leakage. If evidence of leakage, inject

correct compound simultaneously

rotating plug.

After installation or overhaul check

daily for one week and then at three

monthly intervals.

3MTechnical

1.Operational

status.

Valve normally closed, rotate

handwheel to ensure freedom of

movement.

Close valve (if system allows) to

check seat tightness. If valve

normally closed, drop differential

pressure to 1 bar or less (if system

allows) and partially rotate to check

for freedom from galling seats.

3M 1.Operational

status.

Valve normally closed, rotate

handwheel to ensure freedom of



not jam.

Close valve (if system allows) to

check seat tightness. If valve

normally closed, drop differential

pressure to 1 bar or less (if system

allows) and partially rotate to check

for freedom from galling seats.

3MOther

Page 557 of 614

Previous

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Reason For

Change

2. Gland leakage. Check, within first week slightly


leakage still occurs, replace gland.








the valve stem.

1W Deleted

3. Body leakage. Check for body/cover joint leakage

and tighten nuts to stop.

As a matter of routine any visible

signs of leakage should be reported

to the site supervisor.

12M 2. Body leakage. Check for body/cover joint leakage

and tighten nuts to stop.

As a matter of routine any visible

signs of leakage should be reported

to the site supervisor.

1MOther

4. Overall

condition.





due to pipe strains, ground

settlement, poor joints or poor pipe

supports.

12M 3. Overall

condition.





due to pipe strains, ground

settlement, poor joints or poor pipe

supports.

12MOther

1. Operational

status.




dirt or damage.

Important: Great care must be

exercised to avoid injury to

personnel. Check that discharge is

to free space or if piped, that pipe

outlet is not directed to personnel.

NOTE: Check with insurance

company for frequency of

mandatory checks.

3M 1. Operational

status.




dirt or damage.

Important: Great care must be

exercised to avoid injury to

personnel. Check that discharge is

to free space or if piped, that pipe

outlet is not directed to personnel.

Check with insurance company for

frequency of mandatory checks.

3MOther

2. Bursting discs

(if ftted).

Check condition, report.12M 3. Bursting discs

(if fitted).

Check condition, report. The Competent Person should be

contacted for the routine

replacement frequency for the

bursting discs

12MOther

Steam pressure

reducing valves

It is recommended that this type of

valve should be dismantled for a

complete overhaul every twelve to

eighteen months, preferably with the

valve removed from the pipeline.

18M Steam pressure

reducing valves

The written scheme of examination


Stripped down, overhauled and then



Pressure Regulation

12MLegislative

Boiler valves Note: See also BOILERS for safety

valves.

Boiler valves The written scheme of examination


Stripped down, overhauled and then



Pressure Regulation

Legislative

1. Main stop

valve.

Lap seats, inspect for corrosion,

reset valve at correct set pressure

and carry out accumulation test.

12M 1. Safety valve. Lap seats, inspect for corrosion,

reset valve at correct set pressure

and carry out accumulation test.

12MOther

3. Water level

controls.

Blowdown and check operation. This should be carried out daily. Deleted

4. Sequencing

valve.

Clean and lap seats, check for

ease of operation.

Note: See also BOILERS for safety

valves.

12M 3. Sequencing

valve.

Clean and lap seats, check for ease

of operation.

See also Boilers SFG 05-01 for

safety valves.

12MTechnical

5. Water level

gauge

Refit sight glass, repack cock plugs

and check for ease of operation.

Aggressive site conditions may

require increased frequency of

these items. Gauge glasses should

be regularly replaced before they

break.

6M 4. Water level

gauge (sight

glasses)

Refit sight glass, repack cock plugs

and check for ease of operation

and isolation.

Aggressive site conditions may

require increased frequency of

these items. Gauge glasses should

be regularly replaced before they

break.

6MTechnical

Page 558 of 614

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Reason For

Change

Radiator Valves

TRVs

Check air temperature calibration



around sensor is resticted or


thermal gains.




12M Radiator Valves

TRVs

Check air temperature calibration





thermal gains.




12MOther

Page 559 of 614

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Change

TAP AND OUTLET FITTINGS61-02 61-02 TAP AND OUTLET FITTINGS

A large range of outlet fittings suitable for high and low pressure supplies are fitted in this country ,

most requiring little or no regular maintenance except for the replacement of leaking washers, ceramic

disc cartridges or the repacking of spindle glands which should be done if warranted.

Other fittings which are available with a variety of special outlets, aerators, ball outlet joints, flow

straightens, flexible hoses, jet sprays, hand sprays, time delays, dechlorinators, filters and the like,

should be checked and cleaned in accordance with the manufacturer’s instructions , using the

manufacturer’s recommended spares.

Special care against damaging finishes should be taken with all terminal fittings, especially where gold

plating or powder coating has been used.

A large range of outlet fittings suitable for high and low pressure supplies are fitted in this country ,

most requiring little or no regular maintenance except for the replacement of leaking washers, ceramic

disc cartridges or the repacking of spindle glands which should be done if warranted.

Other fittings which are available with a variety of special outlets, aerators, ball outlet joints, flow

straightens, flexible hoses, jet sprays, hand sprays, time delays, dechlorinators, filters and the like,

should be checked and cleaned in accordance with the manufacturer’s instructions , using the

manufacturer’s recommended spares.

Special care against damaging finishes should be taken with all terminal fittings, especially where gold

plating or powder coating has been used.

Other


1. Operational

status.

Operate head to ensure the

stopcock or tap is operating

correctly. If normally open, close

and then re-open.

Clean exposed stem prior to

operation. If cock or tap fails to

isolate water supply, re-washer and

reset as necessary.

12M 1. Operational

status.



correctly. If normally open, close,

check that the flow of fluid stops

and then re-open. When fully open,


does not jam.




reset as necessary.

12MTechnical

1.Operational

status.

Operate handwheel or stem to test


position. If normally open close

valve and re-open.

To comply with the Water Bye-law,

stop valves must not be less

suitable for the purpose than those

which comply with: BS 1010, BS

5433 or BS 5163 .

12M 1.Operational

status.




valve and re-open. When fully

open, close valve 1/2 turn to ensure

valve does not jam.

To comply with the Water Bye-law,

stop valves must not be less

suitable for the purpose than those

which comply with: BS 1010-2:1973,

BS 5433:1976 or BS 5163 -1 & 2:

2004

12MTechnical

Page 560 of 614

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Change

SERVICE VALVES61-03 61-03 SERVICE VALVES


1. Operational

status.




and then re-open.




reset as necessary.

12M 1. Operational

status.




and then re-open. When fully open,


does not jam.




reset as necessary.

12MOther

1. Operational

status.




valve and re-open.

To comply with the Water

Regulations, stop valves must be

WRC approved and must not be

less suitable for the purpose than

those which comply with: BS 1010,

BS 5433 or BS 5163.

12M 1. Operational

status.




valve and re-open. When fully

open, close valve 1/2 turn to ensure

valve does not jam.

To comply with the Water

Regulations, stop valves must be

WRC approved and must not be

less suitable for the purpose than

those which comply with: BS 1010,

BS 5433 or BS 5163.

12MOther

Page 561 of 614

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Reason For

Change

COMBINATION TAP ASSEMBLIES, MIXING VALVES/TAPS61-04 61-04 COMBINATION TAP ASSEMBLIES, MIXING VALVES/TAPS

Note: The frequency and extent of attention required will vary according to the prevailing site and

operational conditions, however the following guideline schedule is suggested to cover average duty

and site conditions. For higher risk environments, e.g. Healthcare, more frequent checks may be

appropriate. See HVCA publications (ref; DCHI/1) for values and ACOP L8, 2001 for Legionella

information.

The frequency and extent of attention required will vary according to the prevailing site and

operational conditions, however the following guideline schedule is suggested to cover average duty

and site conditions. For higher risk environments, e.g. Healthcare, more frequent checks may be

appropriate. See B&ES (the Building & Engineering Services Association, formerly the HVCA)

publications ref; DCHI/1 Domestic Central Heating Installation Specification for values and ACOP L8,

2000 (www.hse.gov.uk) for Legionella information.

Other


2. Temperature For thermostat and pressure

balanced mixers, blend temperature

should stabilise quickly and remain

with SYMBOL 177 \f 'Symbol' \s 12

2 oC of set value. For manual

mixers, refer to commissioning data.

TO BE CHECKED AS TO WHAT IS

MEANT!

2. Temperature For thermostat and pressure

balanced mixers, blend temperature

should stabilise quickly and remain

within 1oC to 2oC of set value. For

manual mixers, refer to

commissioning data.

At water temperatures above 50°C

there is a risk of scalding, which

increases with temperature and time

of contact. In premises used by

persons at risk, e.g. old people, sick

persons, people with reduced

mental capacity, reduced mobility,

anyone with sensory impairment

and children, fail safe

thermostatically controlled mixing

valves must be used. Department of

Health, HTM 04-01 Part A sets out

the safe water temperatures and

appropriate delivery devices

(TMV`s) over a range of

areas/activities. HS(G)220 Health

and safety in care homes - issued

12/01 (file 357) recommends that

where vulnerable people are at risk

from scalding during whole body

immersion, water temperatures do

not exceed 44°C. This should be

checked by clients`s staff at least

monthly. NHS MES (Model

Engineering Specification) D 08

applies.

0MTechnical

b)

adjustable/pre-set

maximum.

b)

adjustable/pre-set

maximum.

Operate flow controls and check

blend temperature. Check

maximum and minimum blend

temperature.

6MTechnical

Page 562 of 614

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Reason For

Change

4. Temperature

control.

Operate mixer at blend

temperature, then open other local

cold outlets off common supply.

Check shift in blend temperature

with reference data compiled at the

commissioning stage.

6M 4. Temperature

control.

Operate mixer at blend

temperature, then open other local

cold outlets off common supply.















Health, HTM 04-01 Part A chapter 9

table 4 on page 31 sets out the safe

water temperatures and appropriate

delivery devices (TMV`s) over a

range of areas/activities. HS(G)220

Health and safety in care homes -

issued 12/01 (file 357) recommends

that where vulnerable people are at

risk from scalding during whole body



checked by client`s staff at least



applies.

6MTechnical

8. Spray heads

(showers).

Check spray pattern and flow rate.

Clean as appropriate.

Note ACOP L8, 2001 applies.3M 8. Spray heads

(showers).

Check spray pattern and flow rate.

Clean and descale as appropriate.

ACOP L8, 2000 (www.hse.gov.uk)

applies.

3MOther

Page 563 of 614

Previous

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Reason For

Change

a) ) temperature

control, b) )flow

control(s), c) )inlet

check valves, d)

)automatic drain

valve.

a) ) temperature

control, b) )flow

control(s), c) )inlet

check valves, d)

)automatic drain

valve.

Operate mixing valve at blend

temperature, then isolate cold

supply. Operate fully and check for

effective closure. Check effective

operation.


























checked by clients staff at least



applies.

Technical

Page 564 of 614

Previous

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Reason For

Change

SHOWER VALVES61-05 61-05 SHOWER VALVES


agreed with client.


with client. For higher risk environments, e.g. Healthcare, more frequent checks may be appropriate.

See B&ES (the Building & Engineering Services Association, formerly the HVCA) publications ref;

DCHI/1 Domestic Central Heating Installation Specification for values and ACOP L8, 2000 for

Legionella information.

Technical


2. Thermostat. Check mixed water outlet setting. Ensure digital

thermometer/sensor is immersed in

flowing water, if measurement taken

at shower head. It a requirement

that the sensing device is Certified

as within calibration, a mercury

thermometer must not be used.

6M 2. Thermostat. Check mixed water outlet setting. Ensure digital thermometer/sensor

is immersed in flowing water, if

measurement taken at shower

head. It a requirement that the

sensing device is Certified as within

calibration, a mercury thermometer

must not be used.

6MOther

3. Temperature

limiter.

Check mixed water outlet

temperature at limit safety stop.

Limiter setting 42ºC.6M 3. Temperature

limiter.

Check mixed water outlet

temperature at limit safety stop.

Limiter setting should be set

between 37oC and 46oC depending

on the users.























checked by clients staff at least



applies.

6MTechnical

4. Strainers

(where fitted).

Clean. Limiter setting 42ºC.6M 4. Strainers

(where fitted).

Check and clean.6MOther

Page 565 of 614

VALVES -AUTOMATIC CONTROL

Page 566 of 614

Previous

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Reason For

Change

PRE - MAINTENANCE PROCEDURES62-01 62-01 PRE - MAINTENANCE PROCEDURES

This procedure applies to all types of automatic control valves and requires that before any

maintenance is undertaken all Health and Safety precautions must be adhered to including system

isolation. Care must be taken to ensure that any maintenance does not unduly interfere with

environmental operating conditions.

1. Inspect, where changes, disconnections or unrecorded settings are found, report and discuss with

client.

2. Note any settings made; i.e. min/max travel balancing valve setting etc.

3. Check valve body and fixings for any signs of corrosion or mechanical damage.

4. Check that pipe flange or screw connections are not leaking.

5. Where fitted, check that the actuator yoke and linkages are secure and not bent or damaged.

6. Check correct installation of valve with reference to both type and manufacturer.

There are a large number of valve manufacturers who each call for specific maintenance and

lubrication procedures for their products, to avoid undue repetition in maintenance the following terms

have been used in the schedules.

Manufacturer's maintenance instructions.

Manufacturer's lubrication instructions.






client.

2. Keep note of any settings made; i.e. min/max travel balancing valve setting etc.





7. Check that control cables have been installed with the correct polarity




Manufacturer`s maintenance instructions.

Manufacturer`s lubrication instructions.Technical

Technical

Page 567 of 614

Previous

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Reason For

Change

ROTARY VALVES - Shoe or Slipper62-02 62-02 ROTARY VALVES - Shoe or Slipper






client. 2. Note any settings made; i.e. min/max travel balancing valve setting etc.









Manufacturer's lubrication instructions






client.

2. Keep a note of any settings made; i.e. min/max travel balancing valve setting etc.










Manufacturer`s lubrication instructions

Technical


1. Operational

status


rotary travel. Refer to


instructions.

Check by operation of the actuator,

see - ACTUATORS - MOTOR

DRIVEN.

12M 1. Operational

status




instructions.


see - Acuators - motor driven SFG

1-06.

12MOther

Page 568 of 614

Previous

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Reason For

Change

BUTTERFLY AND BALL VALVES62-03 62-03 BUTTERFLY AND BALL VALVES

Pre-maintenance Procedure


maintenance is undertaken all safety precautions must be adhered to including system isolation. Care

must be taken to ensure that any maintenance does not unduly interfere with environmental operating

conditions.


client.





6. Check correct installation of valve with reference to both type and manufacturer








maintenance is undertaken all safety precautions must be adhered to including system isolation. Care

must be taken to ensure that any maintenance does not unduly interfere with environmental operating

conditions.


client.

2. Keep a note of any settings made; i.e. min/max travel balancing valve setting etc.




6. Check correct installation of valve with reference to both type and manufacturer






Manufacturer`s lubrication instructions.

Technical


1. Operational

status




instructions.


see - ACTUATORS - MOTOR

DRIVEN.

12M 1. Operational

status




instructions.



1-06.

12MOther

Page 569 of 614

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Reason For

Change

SELF ACTING and THERMAL VALVES62-04 62-04 SELF ACTING and THERMAL VALVES

Pre-maintenance procedure






client.

2. Note any settings made; i.e. min/max travel










Pre-maintenance procedure






client.

2. Keep a note of any settings made; i.e. min/max travel











Technical


1. Operational

status.

Check for correct travel. Check

integrity of capillary. Refer to


instructions.

Refer to - motor driven actuators. In

some cases manual override is only

available by removal of actuating

head.

12M 1. Operational

status.

Check for correct travel. Check

integrity of capillary. Refer to


instructions.



1-06. In some cases manual

override is only available by removal

of actuating head.

12MOther

Page 570 of 614

Previous

Version

Updated

Version

Reason For

Change

SOLENOID VALVES62-05 62-05 SOLENOID VALVES







client.

















client.

2. keep a note of any settings made; i.e. min/max travel balancing valve setting etc.











Other

Page 571 of 614

Previous

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Updated

Version

Reason For

Change

SEAT VALVES62-07 62-07 SEAT VALVES


1. Operational

status.


linear movement.


Motor Driven Actuators. See

ACTUATORS-Motor Driven.

12M 1. Operational

status.


linear movement.



1-06.

12MOther

Page 572 of 614

VEHICLE ACCESS

Page 573 of 614

Previous

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Reason For

Change

UNDERFLOOR HEATING including VEHICLE ACCESS RAMPS63-01 63-01 UNDERFLOOR HEATING including VEHICLE ACCESS RAMPS


3. Controls. Check operation. For more detailed maintenance

instructors, see relevant section.

12M 3. Controls. Check operation. For more detailed maintenance

instructors, see relevant section

Control panels and controllers SFG

14.

12MOther

4. Frost

actuation.

Check sensor, if faulty, replace.

Check operation.

For more detailed maintenance

instructions, see relevant section.

12M 4. Frost

actuation.

Check sensor, if faulty, replace.

Check operation.

12MOther

Page 574 of 614

Previous

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Reason For

Change

AUTOMATIC VEHICLE BARRIER63-02 63-02 AUTOMATIC VEHICLE BARRIER

Inform client before withdrawing or restoring electricity supply to barrier.

Isolation electrically should be secure, i.e. it should either be at the point of work or precautions should

be taken to prevent anyone else switching on again when work is in progress. This may require a

Permit To Work.

Inform client before withdrawing or restoring electricity supply to barrier.

Isolation electrically should be secure, i.e. it should either be at the point of work or precautions should

be taken to prevent anyone else switching on again when work is in progress. This may require a

Permit To Work.

Other


6. Motor

overload.



(See also MOTORS.)6M 6. Motor

overload.



See also Motors SFG39-01.6MOther

Page 575 of 614

VENTILATION ANCILLARIES

Page 576 of 614

Previous

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Reason For

Change


1 Local Exhaust Ventilation (LEV) – fume extract

In bus and vehicle garages and many other work areas where the build up of dangerous fumes may

occur, special air extraction systems are often required/installed. These may be fixed, flexible or

mobile installations often incorporating controls and sensors. It is important to observe that the

maintenance, examination and testing of local exhaust ventilation HSG 258, 2008 applies under the

COSHH Regulations. It is esential to ensure that any discharges do not cause harm to others,

discharge areas are to be checked as safe.

2 Life supporting systems

This equipment is essential in hazardous areas and it is vital that it must be well maintained. Because

of its importance maintenance of such equipment must be carried out by qualified specialist

personnel.

1 Local Exhaust Ventilation (LEV) – fume extract

In bus and vehicle garages and many other work areas where the build up of dangerous fumes may

occur, special air extraction systems are often required/installed. These may be fixed, flexible or

mobile installations often incorporating controls and sensors. It is important to observe that the

maintenance, examination and testing local exhaust ventilation highlighted in HSG 258: 2008

(www.hse.gov.uk), applies under the COSHH Regulations. It is essential to ensure that any

discharges do not cause harm to others, discharge areas are to be checked as safe.

2 Life supporting systems

This equipment is essential in hazardous areas and it is vital that it must be well maintained. Because

of its importance maintenance of such equipment must be carried out by qualified specialist

personnel.

Other

Page 577 of 614

Previous

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Reason For

Change

MOTOR DRIVEN EXHAUST HOSE REEL64-02 64-02 MOTOR DRIVEN EXHAUST HOSE REEL


1. Extract Fans Carry out routine maintenance of

the extract fans. For Guidance see

Fans - extract SFG 20-08

Depending on what the fans are

extracting, the maintenance

frequencies may need to be

increased.

6MAdded

9 System Undertaken a Thorough test and

Inspection of the system in

accordance with Section 10 of

ACOP 258:2008. Thorough’ means

careful, methodical, painstaking

and complete. The task should

only be carried out by a competent

person. The term Competence is

defined Chapter 2 and the

Appendix 1 of the ACOP 258:2008

The maximum time between tests of

LEV systems is set down in COSHH

and for most systems this is 14

months (see the exceptions in Table

18 of the ACOP 258:2008). In

practice this is normally taken to

mean annually. If wear and tear on

the LEV system is liable to mean

that the system effectiveness will

degrade between tests then

thorough examinations and tests

should be more frequent.

12MAdded

1. Hose, both

starter hose and

extensions, if fitted

and hose stop.

Check for flattening and damage.

Check condition of hose stop and

location on hose.

12M 2. Hose, both

starter hose and

extensions, if fitted

and hose stop.



location on hose.

12MOther

2.Control box and

operation.

Check functions, i.e. up, down,

on/off fan if RCR reel fitted with

auto fan contractor.

With pendant control up/down only.

Remote control reel (RCR) only has

ability for:- on hose lowering fan will

start and on retraction will switch off

only if reel either a) combi-unit, or b)

fitted with fan contractor.

12M 3.Control box and

operation.

Check functions, i.e. up, down,

on/off fan if RCR reel fitted with

auto fan contractor.

With pendant control up/down only.

Remote control reel (RCR) only has

ability for:- on hose lowering fan will

start and on retraction will switch off

only if reel either a) combi-unit, or b)

fitted with fan contractor.

12MOther

3. Upper and

lower switches.

Check function and condition of

upper and lower limit switch.

Lower limit switch activates when

reel has lowered its full length of

hose.

12M 4. Upper and

lower switches.

Check function and condition of

upper and lower limit switch.

Lower limit switch activates when

reel has lowered its full length of

hose.

12MOther

4. Infrared

transmitter.

Check functions and condition. Test

battery and replace if necessary.

Applies to RCR only.12M 5. Infrared

transmitter.

Check functions and condition.

Test battery and replace if

necessary.

Applies to RCR only.12MOther

5. Main drive

gear.

Check overall condition of gear for

wear.

Gear will be visible on removal of

control cover.

12M 6. Main drive

gear.

Check overall condition of gear for

wear.

Gear will be visible on removal of

control cover.

12MOther

6.Swivel coupling

and drive motor.

Check for free drive/rotation of reel. (See also MOTORS12M 7 .Swivel coupling

and drive motor.

Check for free drive/rotation of reel.12MOther

7. Nozzle. Check damper for damage and

operation of spring. Check

operation of grip and general

condition of nozzle.

Mole grip type clamp only available

on rubber/steel construction nozzle.

12M 8. Nozzle. Check damper for damage and





on rubber/steel construction nozzle.

12MOther

Page 578 of 614

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Reason For

Change

SPRING RECOIL HOSE REEL64-03 64-03 SPRING RECOIL HOSE REEL


1. Hose, both

starter hose and

extension, if fitted,

and hose stop.



location on hose.

12M 2. Hose, both

starter hose and

extension, if fitted,

and hose stop.



location on hose.

12MOther

2.Spring and

ratchet.

Check recoiling action of reel and

correct tensioning of spring. Check

operation of ratchet.

12M 3.Spring and

ratchet.

Check recoiling action of reel and

correct tensioning of spring. Check

operation of ratchet.

12MOther

3.Swivel coupling

and drum.

Check for free movement/rotation

of drum.

12M 4.Swivel coupling

and drum.

Check for free movement/rotation

of drum.

12MOther

4. Auto on/off

switch for fan, if

fitted.

Check location and mounting of two

switch trigger blocks on drum side.

Check operation of switch for

control fan.

12M 5. Auto on/off

switch for fan, if

fitted.

Check location and mounting of two

switch trigger blocks on drum side.

Check operation of switch for

control fan.

12MOther

5.

Suspension/mount

ing bolts.

Check tension on mounting bolts

and nip up if required.

12M 6.Suspension/mou

nting bolts.



12MOther






on rubber/steel constructed nozzles.







12MOther







increased.

6MAdded

9 System Undertaken a thorough test and



ACOP 258:2008. The task should









18 of the ACOP 258:2008). In








12MAdded

Page 579 of 614

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Change

MOBILE DUST SEPARATOR FOR SPOT EXTRACTION64-04 64-04 MOBILE DUST SEPARATOR FOR SPOT EXTRACTION








increased.

6MAdded

8. System Undertaken a thorough test and












18 of the ACOP 258:2008). In








12MAdded

9. Mobile Unit Undertake a test of the unit

(Portable Appliance Test) in line

with the requirements of the

Electricity at Work Act 1989

(Regulation 4(2)). For Guidance

see Portable equipment PAT testing

SFG 42-01.

12MAdded

1. Suction and

interconnecting

hoses.

Check condition for damage or

flattening.

12M 2. Suction and

interconnecting

hoses.


flattening.

Frequency could be greater

depending on the process that the

LEV has been installed for. See

table 18 in HSG 258: 2008

12MOther

2. Mounting. Check tension on mounting bolt

between handle, dust collector,

plus motor and filter housing.

12M 3. Mounting. Check tension on mounting bolt

between handle, dust collector, plus

motor and filter housing.

12MOther

3. Switch cable

and motor.

Check full length of cable for

damage and operation of switch.

Check for smooth running of motor.

12M 4. Switch cable

and motor.




12MOther

4. Pressure

reduction hose.

Check condition and connections of

small bore hose.

12M 5. Pressure

reduction hose.


small bore hose.

12MOther

5. Gaskets and

cyclone mounting

rod.

Check top of cyclone for debris and

correct location of mounting rod.

For access, unclip lid assembly from

over-bin and unbolt cyclone plate.

After replacing lid and cyclone

arrangement check seating of

gasket.

12M 6. Gaskets and

cyclone mounting

rod.







gasket.

12MOther

6. Filter. Check condition and replace as

necessary. On replacement of filter

check condition of gasket.

Test pressure of supplies and

ensure they conform to the


and record results on

commissioning sheet.

12M 7. Filter. Check condition and replace as








12MOther

Page 580 of 614

Previous

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Reason For

Change

MOBILE ELECTRONICALLY CONTROLLED CYCLONE SEPARATOR64-05 64-05 MOBILE ELECTRONICALLY CONTROLLED CYCLONE SEPARATOR


1. Suction and

interconnecting

hoses.


flattening.

12M 2. Suction and

interconnecting

hoses.


flattening.

12MOther

2. Mounting. Check tension on mounting bolt to

trolley and tighten as necessary.

12M 3. Mounting. Check tension on mounting bolt to

trolley and tighten as necessary.

12MOther

3. Control box

and cable.

Check functions of control box, e.g.

on/off. Check full length of cable for

damage.

When running check correct

direction of rotation of fan.

12M 4. Control box

and cable.

Check functions of control box, e.g.

on/off. Check full length of cable

for damage.

When running check correct

direction of rotation of fan.

12MOther

4. Pre-filter. Visually check condition of main

gear wheel on filter and drive gear

on cleaning handle. Visually check

condition of pre-filter and seating of

gasket.

For access, pull back rubber collar

at the top of the filter housing,

remove retaining screws and

carefully remove filter cover.

12M 5. Pre-filter. Visually check condition of main

gear wheel on filter and drive gear

on cleaning handle. Visually check

condition of pre-filter and seating of

gasket.

For access, pull back rubber collar

at the top of the filter housing,

remove retaining screws and

carefully remove filter cover.

12MOther

5. Filter. Check condition of flipstrip filter and

replace if necessary. Ensure

correct seating of gasket.

Note:- Discarded filter elements

should be placed in sealed bags for

disposal. Waste Disposal

Regulations advance \U 0.0 may

apply - WHAT IS MEANT HERE?

12M 6. Filter. Check condition of flipstrip filter and

replace if necessary. Ensure

correct seating of gasket.

Discarded filter elements should be

placed in sealed bags for disposal.


apply

12MOther

6. Cone valve. Check condition and operation of

valve.

This valve should rise when the unit

is switched on and lower as the

vacuum decreases when the unit is

switched off.

12M 7. Cone valve. Check condition and operation of

valve.

This valve should rise when the unit

is switched on and lower as the

vacuum decreases when the unit is

switched off.

12MOther







increased.

6MAdded













18 of the ACOP 258:2008). In








12MAdded






see Portable equipment PAT testing

SFG 42-01.

12MAdded

Page 581 of 614

Previous

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Reason For

Change

VEHICLE EXHAUST RAIL SYSTEM64-06 64-06 VEHICLE EXHAUST RAIL SYSTEM








increased.

6MAdded













18 of the ACOP 258:2008). In








12MAdded

1. Hose on

suction unit.

Check condition of hose for

flattening and damage.

Examine both upper and lower

hoses.

12M 2. Hose on

suction unit.

Check condition of hose for

flattening and damage.

Examine both upper and lower

hoses.

12MOther

2. Safety break

coupler.

Check overall condition of coupling

and location of and condition of

spring clips between retaining pins.

Access to spring clips is achieved by

pulling back centre rubber collar.

12M 3. Safety break

coupler.

Check overall condition of coupling

and location of and condition of

spring clips between retaining pins.

Access to spring clips is achieved by

pulling back centre rubber collar.

12MOther













12MOther

4. Suction trolley. Check trolley for free rolling without

play movement.



12M 5. Suction trolley. Check trolley for free rolling without

play movement.



12MOther

5. Auto

disconnect

system.

Check operation by clamping a

small piece of steel or alternative

between jaws of clamp. Slide trolley

to disconnect position and ensure

correct location.

Not fitted on manual disconnect

units. Clamp jaws should open on

ball assembly location in

disconnection brackets.

12M 6. Auto

disconnect

system.

Check operation by clamping a

small piece of steel or alternative

between jaws of clamp. Slide

trolley to disconnect position and

ensure correct location.

Not fitted on manual disconnect

units. Clamp jaws should open on

ball assembly location in

disconnection brackets.

12MOther

6. Rubber seal. Check overall condition. May be lubricated with silicone

spray.

12M 7. Rubber seal. Check overall condition. May be lubricated with silicone

spray.

12MOther

7.

Suspension/Mount

ing bolts.



May be lubricated with silicone

spray.

12M 8.

Suspension/Mount

ing bolts.



May be lubricated with silicone

spray.

12MOther

8. Duct

connections.

Check seal and condition of end

caps and fan duct connection pipe.

12M 9. Duct

connections.

Check seal and condition of end

caps and fan duct connection pipe.

12MOther

Page 582 of 614

Previous

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Reason For

Change

64-07 WOOD DUST EXTRACTION



the extract fans. For guidance see

Fans - Extract SFG 20-08




increased.

6MAdded

2. System -

General

Carry out operation check of unit

and note any unusual noises,

vibrations or odours.lean or replace

filters as required.

Check filter retaining frames are in

good condition.

Clean out any dust or shavings

trapped witin the system.

Wipe down fan impeller.

Check motor airways are clear.

Check ductwork and inlet guards

are in good condition, free from

leaks, and allow unimpeded

removal of dust.

Check all brackets, fixings and bolts

are secure.

Check discharge area is clean and

tidy.

Check bag shaker and bag

securing clips.

Test control functions.

Carry out operation check of unit

and note any unusual noises,

vibrations or odours.lean or replace

filters as required.

6MAdded

3. Suction and

interconnecting

hoses.


flattening.

Frequency could be greater

depending on the process that the

LEV has been installed for. See

table 18 in HSG 258: 2011

12MAdded

4. Mounting. Check tension on mounting bolt

between handle, dust collector, plus

motor and filter housing.

12MAdded

5. Switch cable

and motor.




Check controls are in good

condition. Check local isolator for

signs of overheating and smooth

operation. Open isolator and clean

if required.

12MAdded

6. Pressure

reduction hose.


small bore hose.

12MAdded

7. Gaskets and

cyclone mounting

rod.







gasket.

12MAdded

Page 583 of 614

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Change

8. Filter. Check condition and replace as








12MAdded

9. Lighting Check illumination in booths and

hoods if appropriate.

12MAdded


inspection of the system in











18 of the ACOP 258:2011). In








12MAdded






see portable equipment PAT testing

SFG 42-01.

12MAdded

12. Hoods,

canopies and duct

interiors

Check ductwork condition,

especially flexible ducts clean as

appropriate. Check cleanliness of

hoods, especially canopies and

clean as appropriate. Check the

mechanical integrity, eg corrosion,

damage, seals, dampers, sash

suspensions etc.

Check the make-up air is working

without draughts or blockages.

12MAdded

13. Extract

Explosion

Suppression

System

Carry out annual service in strict


instructions

In accordance with BS EN

14373:2005 Explosion suppression

systems.

12MAdded

Page 584 of 614

WATER TREATMENT

Page 585 of 614

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Reason For

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Water may be used for a variety of purposes within buildings, some of the applications will require the

water supplied to the building to be treated in order to render it suitable for the purpose for which it is

to be used. The maintenance requirements for water treatment plants will vary and be specific to the

equipment used and the nature of the application.

Potable or Drinking Water

Public water supplies

Buildings in the UK are usually supplied with ‘towns mains’ portable water from a water supply

undertaker. (Water Companies in England, Regional Councils in Scotland and the Department of the

Environment in Northern Ireland).

The quality of potable water is controlled by legislation and should require no further treatment before

consumption provided that the water is fed directly to the point of use. However point of use water

treatment devices may be found on these supplies.

Private water supplies

Buildings may have their own water supply such as a borehole or a well, or may receive water from a

private supply which services more than one building. These water supplies may require treatment in

order to make them potable.

Main uses of Treated Water

Hot water and steam raising

Most water supplies require some form of treatment in order to avoid the scaling or corrosion of heat

exchange surfaces caused by dissolved solids or impurities in the water.

Air conditioning and heating

In air-conditioned buildings treated water is used in the cooling system water. This is essential in order

to ensure and maintain effective operation of the equipment. Proper treatment has a bearing on

energy costs, the implementation of the HASAWA and legionellosis control. Cooling towers that have

not been maintained regularly must be considered as HAZARDOUS and must not be maintained by

persons who may be susceptible to Legionella. (For detailed comment see HEAT REJECTION).

Circulatory heating and cooling systems may be provided with automatic or manual dosing equipment

WATER TREATMENT AND CONDITIONING

Humidification

Certain types of humidification systems also have water treatment equipment which requires regular

maintenance to ensure proper humidification performance. (For individual HUMIDIFIERS see relevant

section).

Cold water services

In certain buildings cold water used for non-portable cold water services may be treated.

Recreational and therapeutic applications

Facilities such as swimming pools, saunas, whirlpool, spa baths and hydrotherapy pools, all require

treatment of the water to maintain microbiological and aesthetic conditions suitable for their purpose.

Treatment Categories

Water treatment falls into the following categories:

A Ion exchange

1. Base exchange softening - commercial

2. Base exchange softening - domestic

3. De-ionisation (de-mineralisation) including de-alkalisation

B Filtration conditioning and pH treatment

Central plant

1. Iron removal

2. pH correction

3. Active carbon filtration

4. Turbidity removal (clarification)

Point of use


6. Bacteria removal filters

7. Sediment removal filters

Water may be used for a variety of purposes within buildings, some of the applications will require the

water supplied to the building to be treated in order to render it suitable for the purpose for which it is

to be used. The maintenance requirements for water treatment plants will vary and be specific to the

equipment used and the nature of the application.

Potable or Drinking Water

Public water supplies

Buildings in the UK are usually supplied with ‘towns mains’ potable water from a water supply

undertaker. (Water Companies in England, Regional Councils in Scotland and the Department of the

Environment in Northern Ireland).

The quality of potable water is controlled by legislation and should require no further treatment before

consumption provided that the water is fed directly to the point of use. However point of use water

treatment devices may be found on these supplies.

Private water supplies

Buildings may have their own water supply such as a borehole or a well, or may receive water from a

private supply which services more than one building. These water supplies may require treatment in

order to make them potable.

Main uses of Treated Water

Hot water and steam raising

Most water supplies require some form of treatment in order to avoid the scaling or corrosion of heat

exchange surfaces caused by dissolved solids or impurities in the water.

Air conditioning and heating

In air-conditioned buildings treated water is used in the cooling system water. This is essential in order

to ensure and maintain effective operation of the equipment. Proper treatment has a bearing on

energy costs, the implementation of the HASAWA (www.hse.gov.uk) and legionellosis control. Cooling

towers that have not been maintained regularly must be considered as HAZARDOUS and must not be

maintained by persons who may be susceptible to Legionella. (For detailed comment see Heat

rejection SFG 30-02.

Circulatory heating and cooling systems may be provided with automatic or manual dosing equipment

WATER TREATMENT AND CONDITIONING

Humidification

Certain types of humidification systems also have water treatment equipment which requires regular

maintenance to ensure proper humidification performance. (For individual Humidifiers including

disinfection procedures SFG 33-01 to 33-07 see relevant section).

Cold water services

In certain buildings cold water used for non-portable cold water services may be treated.

Technical

Page 586 of 614

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Reason For

Change

8. Reverse osmosis (see Section D)

9. Ultra violet disinfection (see Section E)

C Chemical dosing

1. Chlorination

2. Bromination

3. Oxygen scavenging, corrosion and scale inhibitors

4. Phosphate dosing

5. Biocide

D Reverse osmosis

1. Reverse osmosis purification

E Ultra violet

F Ozonation

Recreational and therapeutic applications

Facilities such as swimming pools, saunas, whirlpool, spa baths and hydrotherapy pools, all require

treatment of the water to maintain microbiological and aesthetic conditions suitable for their purpose.

Treatment Categories

Water treatment falls into the following categories:

A) Ion exchange

1. Base exchange softening - commercial

2. Base exchange softening - domestic

3. De-ionisation (de-mineralisation) including de-alkalisation

B) Filtration conditioning and pH treatment

Central plant

1. Iron removal

2. pH correction


4. Turbidity removal (clarification)

Point of use


6. Bacteria removal filters

7. Sediment removal filters

8. Reverse osmosis (see Section D)

9. Ultra violet disinfection (see Section E)

C) Chemical dosing

1. Chlorination

2. Bromination

3. Oxygen scavenging, corrosion and scale inhibitors

4. Phosphate dosing

5. Biocide

6. Salinity (Brine systems)

Page 587 of 614

Previous

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Reason For

Change

D) Reverse osmosis

1. Reverse osmosis purification

E) Ultra violet

F) Ozonation

Page 588 of 614

Previous

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Reason For

Change

ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - commercial65-02 65-02 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - commercial

Note: Maintenance of water treatment plant is very important to avoid scaling of heat exchange

surfaces in plant which can lead to deposits and subsequent blockage of outlet fittings, in addition it

can lead to energy wastage and increased costs. The operator should refer to and be familiar with the

manufacturer's operator's handbook and follow the manufacturer's recommendations regarding the

frequency at which the various maintenance functions should be carried out. These can vary

depending on the type of plant and manufacturer.

Maintenance of water treatment plant is very important to avoid scaling of heat exchange surfaces in

plant which can lead to deposits and subsequent blockage of outlet fittings, in addition it can lead to

energy wastage and increased costs. The operator should refer to and be familiar with the

manufacturer`s operator`s handbook and follow the manufacturer`s recommendations regarding the



In addition to the routine checks below the client`s operator will undertake operational tasks including

checking salt levels in the salt saturator/brine tank, check and record, in the log book, inlet water

hardness and outlet (soft) water hardness. The operator will check for leaks and if present, locate

source and report (leaks on control valves and vessel, manufacturer`s advice should be sought).

Other


1. Salt saturator

(may be combined

with brine tank).

Check salt level and report as

necessary.

In addition to routine checks, the

frequency may be altered by the

client's operator to suit usage.

6M Deleted

2. Brine tank

(where fitted

separately).

Clean as appropriate. Check with

brineometer that brine is fully

saturated.

If brine is not fully saturated, brine

system requires further

investigation. Client should be

advised and matter referred to

manufacturer or equipment supplier.

6M 1. Brine tank

(where fitted

separately).

Clean as appropriate. Check with

brineometer that brine is fully

saturated.

If brine is not fully saturated, brine

system requires further

investigation. client should be

advised and matter referred to

manufacturer or equipment supplier.

6MOther

3. Overflow and

drain.

Clean and clear of debris and dirt.6M 2. Overflow and

drain.

Clean and clear of debris and dirt.6MOther

4. Water leaks. If present, locate source and report. For control valves and vessel,

manufacturer's advice should be

sought.

6M Deleted

5. Inlet water

hardness.

Measure and record in plant log. If the raw water hardness increases

or decreases by more than 5% of

the initially specified level, refer to

manufacturer/supplier's instructions.

6M Deleted

6. Outlet (soft)

water hardness.

Measure from sample of water

taken when softener is in use and

water is flowing.

Treated water may be hard due to

over running or fault condition which

should be rectified.

6M Deleted

7. Electrical

control system

(where fitted).

Check condition of all electrical

connections.

Refer to plant operator's manual.6M 3. Electrical

control system

(where fitted).


connections.

Refer to plant operator`s manual.6MOther

8. Regeneration

sequence.

Put plant into regeneration

sequence and check all stages of

operation.

If system malfunctioning, refer to

manufacturer or supplier.

6M 4. Regeneration

sequence.



operation.

If system malfunctioning, refer to

manufacturer or supplier.

6MOther

9. Pressure drop

over softener

(where provision to

measure exists).

Check and record in plant log. A gradual build up in back pressure

could indicate fouling or breakdown

of the ion exchange medium.

6M 5. Pressure drop

over softener

(where provision

to measure

exists).

Check and record in plant log. A gradual build up in back pressure

could indicate fouling or breakdown

of the ion exchange medium.

6MOther

10. Booster

pumps.

Carry out maintenance programme

as detailed in PUMPS.

6M 6. Booster

pumps.


as detailed in Pumps SFG 45-12

6MTechnical

Page 589 of 614

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11. Ancillary

controls and

probes (where

fitted) a)

conductivity, b)

electro

chlorination.

Inspect for check operation and

report.

6M 7. Ancillary

controls and

probes (where

fitted) a)

conductivity, b)

electro

chlorination.


report.

6MOther

12. Plant. Check overall condition and report. 8. Plant. Check overall condition and report.6MOther

13. Valves. Overhaul individual valves.6M 9. Valves. Overhaul individual valves as

detailed in Valves SFG 61-03

6MTechnical

14. Back flow

prevention

devices.

Check operation. Where operation is between two

tanks, check can be carried out by

observing whether there is a change

of levels of the two tanks.

6M 10. Back flow

prevention

devices.





6MOther

15.

Recommissioning.

Set up flow rates to suit. Report details to client.6M 11.

Recommissioning.

Set up flow rates to suit. Report details to client.6MOther

16. Water test. Final water test taken. Back pressure readings will give

some indication of the condition of

the resin bed. Take sample and

send to laboratory if part of service

schedule agreed with client.

6M 12. Water test. Final water test taken. Back pressure readings will give





6MOther

17. Major

overhaul.

Details should be agreed with client.36M 13. Major

overhaul.

Details should be agreed with client.36MOther

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ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic

(capacity usually below 50 litres)

65-03 65-03 ION EXCHANGE PLANT - BASE EXCHANGE SOFTENING - domestic

(capacity usually below 50 litres)

Maintenance of water treatment plant is very important to avoid scaling of heat exchange surfaces in

plant which can lead to deposits and subsequent blockage of outlet fittings, in addition it can lead to

energy wastage and increased costs. The operator should refer to and be familiar with the

manufacturer`s operator`s handbook and follow the manufacturer`s recommendations regarding the




checking salt levels in the salt saturator/brine tank, check and record, in the log book, inlet water

hardness and outlet (soft) water hardness. The operator will check for leaks and if present, locate

source and report (leaks on control valves and vessel, manufacturer`s advice should be sought).

Added


4. Inlet water

hardness.

Measure and record in plant log,

adjust plant as appropriate.

12M Deleted

5. Outlet (soft)

water hardness.

Measure from sample of water

taken when softener is in use and

water is flowing.

12M Deleted

6. Water leaks. If present, locate source and report. For control valves and vessel,

manufacturer's advice should be

sought.

6M Deleted

7. Electrical

control system

(where fitted).


connections.

6M 4. Electrical

control system

(where fitted).


connections.

6MOther

8. Regeneration

sequence.



operation.

A gradual reduction in service flow

may indicate breakdown of the

medium.

6M 5. Regeneration

sequence.



operation.

A gradual reduction in service flow

may indicate breakdown of the

medium.

6MOther

9. Booster

pumps.


as detailed in PUMPS.

6M 6. Booster

pumps.


as detailed in Pumps SFG 45-12

6MTechnical

10. Ancillary

controls and

probes (where

fitted) a)

conductivity, b)

electro

chlorination.


report.

6M 7. Ancillary

controls and

probes (where

fitted) a)

conductivity, b)

electro

chlorination.


report.

6MOther

11. Back flow

prevention

devices.





6M 8. Back flow

prevention

devices.





6MOther

12.

Recommissioning.

Set up flow rates to suit. Report details to client.12M 9.

Recommissioning.

Set up flow rates to suit. Report details to client.12MOther

13. Water test. Take final water test. Back pressure readings will give





6M 10. Water test. Take final water test. Back pressure readings will give





6MOther

Page 591 of 614

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14. Major

overhaul.

Details should be agreed with client.36M 11. Major

overhaul.

Details should be agreed with client.36MOther

Page 592 of 614

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SPECIAL WATER TREATMENT SYSTEMS65-04 65-04 SPECIAL WATER TREATMENT SYSTEMS

This type of plant is normally serviced by the manufacturer or their agent. This type of plant is normally serviced by the manufacturer or their agent.Other

Page 593 of 614

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FILTRATION, CONDITIONING and pH CORRECTION - central plant65-05 65-05 FILTRATION, CONDITIONING and pH CORRECTION - central plant


1. Feed water

and treated water

iron levels.

Collection samples of feed and

treated water and visually compare

differences in clarity.

If the maximum concentration of iron

in the treated water is specified,

send sample to laboratory for

analysis.

3M 1. Feed water

and treated water

iron levels.

Collection samples of feed and

treated water and visually compare

differences in clarity. It may be of

benefit to compare samples against

a white background.

If the maximum concentration of

iron in the treated water is specified,

send sample to laboratory for

analysis.

3MTechnical

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FILTRATION and CONDITIONING - POINT OF USE65-06 65-06 FILTRATION and CONDITIONING - POINT OF USE


3. Control

isolating valve.

Check operation.12M 3. Control

isolating valve.

Check operation as described in

Valves SFG 61-03

12MTechnical

Bacterial removal

filters. 1. Cartridge

type.

Remove, clean and disinfect

cartridge. Inspect for cracking or

damage. Change cartridge.

If flow drops to an unacceptable

level earlier maintenance may be

necessary. Disinfection may not be

required, refer to manufacturer's

instructions. Interval may be less

than 48m if frequency of cleaning

become unacceptably short.

3M Bacterial removal

filters. 1.

Cartridge type.

Remove, clean and disinfect

cartridge. Inspect for cracking or

damage. Change cartridge.

If flow drops to an unacceptable

level earlier maintenance may be

necessary. Disinfection may not be

required, refer to manufacturer`s

instructions.

3MTechnical

b) control isolating

valve.

Check operation.12M b) control isolating

valve.


Valves SFG 61-03

12MTechnical

3. Control

isolating valve.

Check operation.12M 3. Control

isolating valve.


Valves SFG 61-03

12MTechnical

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REVERSE OSMOSIS65-07 65-07 REVERSE OSMOSIS


5. Valves. Check action. Detailed information on the

maintenance of VALVES, see

relevant section.

6M 5. Valves. Check action. Detailed information on the

maintenance of Valves SFG 61-01.

6MTechnical

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ULTRA VIOLET DISINFECTION UNIT65-08 65-08 ULTRA VIOLET DISINFECTION UNIT

Caution: Ultra violet radiation is dangerous to the eyes, avoid looking directly at the lamp when

illuminated.

Caution: Ultra violet radiation is dangerous to the eyes, avoid looking directly at the lamp when

illuminated.

Other

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OZONATION PLANT65-09 65-09 OZONATION PLANT

Note: This schedule applies to larger size plants producing more than 30 grammes of ozone per hour.

Smaller sized plant should be checked weekly by client's staff

This schedule applies to larger size plants producing more than 30 grammes of ozone per hour.

Smaller sized plant should be checked weekly by client`s staff.

There is a significantly greater risk of hazardous exposure from leaks from larger generators,

producing 2 gms or more Ozone per hour. Adequate health and safety data including emergency

procedures, in the event of human exposure above safe exposure limits should be displayed near the

generating equipment and any plant or equipment supplied by it.

A permit to work system may be in place. In which case, the Authorised person must be contacted and

a Permit issued before any work can commence on the equipment.

Technical


1. Joints and

Unions

All mechanical joints and unions

exposed to ozone should be

opened up and the rubber seals

inspected to check if perishing or

any wear and deformation is

occurring If found, the seals should

be replaced before restarting the

equipment again.

1WAdded

1. Dielectric

tubes and

electrode

assemblies.

Remove ozone generating

modules, inspect and clean

dielectric tubes and electrode

assemblies. All glass tube 'O' rings

must be replaced and steel liners

cleaned

After cleaning and reassembly,

vacuum test to ensure soundness of

both the intermediate tubeplate and

seals.

6M 2. Dielectric

tubes and

electrode

assemblies.

Remove ozone generating

modules, inspect and clean

dielectric tubes and electrode

assemblies. All glass tube `O` rings

must be replaced and steel liners

cleaned

After cleaning and reassembly,

vacuum test to ensure soundness of

both the intermediate tubeplate and

seals.

6MOther

2. Filter cartridge

in main airline from

dryer.

Remove and replace. Inspect 'O'

ring seals, replace if necessary.

6M 3. Filter cartridge

in main airline

from dryer.

Remove and replace. Inspect `O`

ring seals, replace if necessary.

6MOther

3. Dew point

monitor probe.

Check calibration. Refer to manufacturer's instructions.6M 4. Dew point

monitor probe.

Check calibration. Refer to manufacturer`s instructions.6MOther

4. i) solenoid

valves (where

fitted), ii) proximity

switches (where

fitted).

Remove and replace valve seals

and clean valve seats. Check

operation.

See SWITCHES.6M 5. i) solenoid

valves (where

fitted), ii) proximity

switches (where

fitted).

Remove and replace valve seals

and clean valve seats. Check

operation.

See Switches SFG 58.6MOther

5. Suction and

discharge piping.

Check condition, remove and

replace purge pump membrane

and diaphragm.

6M 6. Suction and

discharge piping.

Check condition, remove and

replace purge pump membrane and

diaphragm.

6MOther

6. Cooling water

flow.

Check flow rate and operation of

proximity switch.

Each module should be checked.6M 7. Cooling water

flow.

Check flow rate and operation of

proximity switch.

Each module should be checked.6MOther

7. Ozone

generator air flow.

Check rate and operation of airflow

proximity switch.

6M 8. Ozone

generator air flow.

Check rate and operation of airflow

proximity switch.

6MOther

8. High

temperature

protection circuit.

Check operation.6M 9. High

temperature

protection circuit.


9. Internal

pipework.

Check for leakage or damage.6M 10. Internal

pipework.

Check for leakage or damage.6MOther

Page 598 of 614

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10. Air dryer

control unit.

Check the timing and adjust as

necessary.

6M 11. Air dryer

control unit.

Check the timing and adjust as

necessary.

6MOther

iii) chiller unit (if

fitted),

Check operation. For detailed maintenance of

refrigeration and chilling unit see

CHILLERS .

6M iii) chiller unit (if

fitted),

Check operation. For detailed maintenance of

refrigeration and chilling unit see

Chillers SFG 09.

6MOther

Page 599 of 614

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CHEMICAL DOSING65-10 65-10 CHEMICAL DOSING

Regular dosing of treated water may be carried out manually or automatically on a discrete or

continuous basis. Certain maintenance operations are common for all types of chemical dosing but

specific requirements may apply to individual treatments such as:

Chlorination - Bromination - Oxygen scavenging, corrosion and scale inhibitors - Phosphate dosing -

Biocides

In all cases refer to the manufacturer's instructions. Care should be taken in the storage,

handling, disposal of all chemicals; note that COSHH Regulations apply.

Regular dosing of treated water may be carried out manually or automatically on a discrete or

continuous basis. Certain maintenance operations are common for all types of chemical dosing but

specific requirements may apply to individual treatments such as:

Chlorination - Bromination - Oxygen scavenging, corrosion and scale inhibitors - Phosphate dosing -

Biocides

In all cases refer to the manufacturer`s instructions. Care should be taken in the storage, handling,

disposal of all chemicals; COSHH (www.hse.gov.uk/hthdir/noframes/coshh/index.htm) Regulations

apply.

Other


3. Chemicals. Fill dosing pot to correct level with

appropriate chemical or chemical

solution for application.

Ensure correct type of chemical

treatment is used for application.

Care is required in the handling of

chemicals which should be carried

out in accordance with COSHH

Regulations .

6M 3. Chemicals. If required, fill dosing pot to correct

level with appropriate chemical or

chemical solution for application.

Ensure correct type of chemical

treatment is used for application.

Care is required in the handling of

chemicals which should be carried

out in accordance with COSHH


shh/index.htm) Regulations .

6MTechnical

4. Dosing. Manipulate valves to ensure correct

dosing of the system.

6M 4. Dosing. If Required, Manipulate valves to

ensure correct dosing of the

system.

6MTechnical

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ADIABATIC COOLING - Introductory Information and Procedures65-11 65-11 ADIABATIC COOLING - Introductory Information and Procedures

Whilst legionella bacteria are most active in the temperature range 20 °C to 45 °C, occasions can

occur where growth is promoted even in cold water systems. This can arise where the local

temperature is raised by:

heat build up due to solar gain or the proximity to hot water services, or

the storage capacity is far greater than is necessary. In general terms the storage capacity should not

exceed one day's usage

seasonal variations. in the summertime it is not unusual to have incoming mains supplies exceeding

20 °C. When this occurs systems should be reassessed



mineral substances and it is for this reason that storage cisterns should be free from rust, dust, slime,



published in the Water Fittings and Materials Directory (see Standards List), All new and replacement

water fittings must satisfy Water Supply (water fittings) Regulations 1999 requirements and be listed in

the WRAS directory.

Cleansing of tanks, cisterns and associated pipe work should be followed by full disinfection in

accordance with the procedures laid down in BS 6700 and as per chemical manufacturers

specification

The pipework system should be free of any points where pockets of dirt, slime or sediment can build

up and stagnation occurs.

Adiabatic Cooling

The effectiveness of air cooled heat rejection systems depend on the difference between the air dry

bulb temperature and the refrigerant condensing temperature. The greater this difference the better

the heat rejection. Traditionally large heat rejection systems use cooling towers or evaporative coolers

to reduce the size of the heat rejection equipment as well as the overall energy consumption due to

lower condensing temperatures than those which would be obtained using dry air cooled condensers.

Unfortunately, the water based corrosion, maintenance and health risks such as legionella have

driven the industry towards the use of less efficient dry heat rejection systems . However, the need to

reduce carbon emissions and energy waste has resulted in a resurgence in the use of evaporative

systems.

As an alternative to conventional cooling towers and evaporative condensers, adiabatic dry air coolers

can reduce the refrigerant condensing temperature by lowering the dry bulb temperature of the air

entering the cooler. This is done by spraying a fine mist of water, usually from the town mains supply,

into the airstream prior to it entering the cooler. As the water is evaporated the airstream is cooled.

Ideally the temperature of the air would be reduced to that of the entering wet bulb. However, the

cooling process is probably some 70% effective and so the dry bulb temperature of the air entering

the cooler is likely to be reduced by about 70% of the wet bulb depression. For example, if the

ambient air is at a dry bulb of 30°C and the wet bulb at 20 °C i.e. a wet bulb depression of 10K, the

dry bulb temperature of the air entering the coil would be 30 °C-0.7x10 K, or 23 °C. For a given

cooling duty this could result in a saving of some 15% in the power required by the chiller. This degree

of saving is only possible during the mid summer for as the dry bulb temperature reduces so does the

wet bulb depression. Nevertheless, such savings at a time of maximum load are a considerable

advantage. Although there is some runoff from the cooler due to not all the water supplied being

evaporated, it is much less than the blowdown from a cooling tower of the equivalent duty.

The use of tank fed water can produce a risk of proliferation of legionella within the system and so

mains water is preferred with timed discharges prior to use to drain away static water and added

protection to remove bacterial formation including legionella.

Tests indicated between 20 and 30% {Note. These figures seem quite high in the light of the 15%

given above. Where do they come from?} reduction in peak electrical load for air cooled chillers and

condensers. The potential for energy saving and carbon emission reduction for industry as a whole is

significant and this can be achieved by simply using the tap water.

Maintenance

Adiabatic Cooling

The effectiveness of air cooled heat rejection systems depend on the difference between the air dry

bulb temperature and the refrigerant condensing temperature. The greater this difference the better

the heat rejection. Traditionally large heat rejection systems use cooling towers or evaporative coolers

to reduce the size of the heat rejection equipment as well as the overall energy consumption due to

lower condensing temperatures than those which would be obtained using dry air cooled condensers.

Unfortunately, the water based corrosion, maintenance and health risks such as legionella have

driven the industry towards the use of less efficient dry heat rejection systems . However, the need to

reduce carbon emissions and energy waste has resulted in a resurgence in the use of evaporative

systems.

As an alternative to conventional cooling towers and evaporative condensers, adiabatic dry air coolers

can reduce the refrigerant condensing temperature by lowering the dry bulb temperature of the air

entering the cooler. This is done by spraying a fine mist of water, usually from the town mains supply,

into the airstream prior to it entering the cooler. As the water is evaporated the airstream is cooled.

Ideally the temperature of the air would be reduced to that of the entering wet bulb. However, the

cooling process is probably some 70% effective and so the dry bulb temperature of the air entering

the cooler is likely to be reduced by about 70% of the wet bulb depression. For example, if the

ambient air is at a dry bulb of 30°C and the wet bulb at 20 °C i.e. a wet bulb depression of 10K, the

dry bulb temperature of the air entering the coil would be 30 °C-0.7x10 K, or 23 °C. For a given

cooling duty this could result in a saving of some 15% in the power required by the chiller. This degree

of saving is only possible during the mid summer for as the dry bulb temperature reduces so does the

wet bulb depression. Nevertheless, such savings at a time of maximum load are a considerable

advantage. Although there is some runoff from the cooler due to not all the water supplied being

evaporated, it is much less than the blowdown from a cooling tower of the equivalent duty.

The use of tank fed water can produce a risk of proliferation of legionella within the system and so

mains water is preferred with timed discharges prior to use to drain away static water and added

protection to remove bacterial formation including legionella.

The potential for energy saving and carbon emission reduction for industry as a whole is significant

and this can be achieved by simply using the tap water.

Maintenance

Specific details relating to the risk of Legionellosis are given in the Health and Safety ACOP L 8,2000

,CIBSE publication TM13 2002, HTM 04 Part A & B.

The general guidance is normally to ensure mains water is used. The spray nozzles must be kept

clean and in good working order. Periodic water testing is taken and independently analysed for

bacterial content including legionella. A disinfection device is normally used and a filter system may be

incorporated thus requiring periodic maintenance in accordance with the manufacturer`s instructions.

It is also likely that a discharge solenoid valve is used to ensure only fresh water is used which must

be included in the maintenance procedures. Also wet pads may be used and these need to be kept

clean.

If fitted in health care settings, permission for use must be obtained from infection control.

All maintenance must be logged and signed for within the site water logbook.

All staff are to be fully trained.

Other

Page 601 of 614

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The general guidance is normally to ensure mains water is used. The spray nozzles must be kept

clean and in good working order. Periodic water testing is taken and independently analysed for

bacterial content including legionella. A disinfection device is normally used and a filter system may be

incorporated thus requiring periodic maintenance in accordance with the manufacturer's instructions. It

is also likely that a discharge solenoid valve is used to ensure only fresh water is used which must be

included in the maintenance procedures. Also wet pads may be used and these need to be kept

clean.

If fitted in health care settings, permission for use must be obtained from infection control.

All maintenance must be logged and signed for within the site water logbook.

All staff are to be fully trained.

Page 602 of 614

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ADIABATIC COOLING SYSTEMS65-12 65-12 ADIABATIC COOLING SYSTEMS

Note: Manufacturers O & M manual should be followed at all times. Manufacturers O & M manual should be followed at all times.

Specific details relating to the risk of Legionellosis are given in the Health and Safety ACOP L 8,2000

,CIBSE publication TM13 2002, HTM 04 Part A & B.

Other


1. Mains supply to

unit and farthest

outlet

Take dipslides and incubate at

30°C 48 hours. Record readings on

a graph..

Action required if > 1041W 1. Mains supply to

unit and farthest

outlet

Take dipslides and incubate at 30°C

48 hours. Record readings on a

graph..

Action required if > 10^41WOther

3. Mains supply

unit and farthest

outlet

Take samples and submit to UKAS

accredited laboratory for the

presence of legionella

Action required if > 100 CFU per

Litre

3M 3. Mains supply

unit and farthest

outlet

Take samples and submit to UKAS

accredited laboratory for the

presence of legionella. Testing

should be in accordance with ISO

11731:1998

The frequency of 3 Months is the

maximum period between testing.

More frequent sampling should be

carried out when commissioning a

system and establishing a treatment

programme. Sampling should be

carried out, on a monthly basis, until

it can be shown that the system is

under control.

Action required if > 100 CFU per

Litre. Refer to Table 2 in the ACOP

L8

3MTechnical

Page 603 of 614

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CHLORINE DIOXIDE DOSING FOR DOMESTIC LOWLEVEL INJECTION65-13 65-13 CHLORINE DIOXIDE DOSING FOR DOMESTIC LOWLEVEL INJECTION



temperature is raised by:

heat build up due to solar gain or the proximity to hot water services, or

the storage capacity is far greater than is necessary. In general terms the storage capacity should not

exceed one day's usage

seasonal variations. in the summertime it is not unusual to have incoming mains supplies exceeding

20 °C. When this occurs systems should be reassessed with the likely outcome of increasing regular

flushing to these outlets in a safe manner with minimal aerosolation.






published in the Water Fittings and Materials Directory (see Standards List), All new and replacement

water fittings should satisfy Water Supply (water fittings) Regulations 1999 requirements and be listed

in the WRAS directory.


accordance with the procedures laid down in BS 6700 and as per chemical manufacturers

specification


up and stagnation can occur.

When temperature problems are encountered and remedial works are not practical in order to

engineer out the problems, Chlorine Dioxide Dosing can be used.

Chlorine dioxide is an oxidising biocide that is capable of reacting with a wide range of organic

substances. In the inactivation of microorganisms, the chlorine dioxide molecule acts as a free radical

(oxidising biocide) that readily bonds with the amino acids (the basic building blocks of proteins, which

form the living cells). This results in their destruction.

Chlorine dioxide as a control measure

The use of chlorine dioxide as a control measure will depend on the design of the systems in use and

their operational history.

There are two aspects to be taken into consideration:

in the cold water distribution system, chlorine dioxide will be injected into the system upstream of all

parts of the distribution, storage and boosting equipment - that is, at the curtilage of the premises.

Backflow prevention is required if chlorine dioxide is injected into a pipe connected to the mains

supply.

in the case of hot water distribution systems with calorifiers/water heater operating conventionally (that

is, at 60°C), there will be a tendency for chlorine dioxide to be lost by "gassing off", especially if the

retention time in a vented calorifier/water heater is long. In most cases, however, some level of total

oxidant should be found in the hot water, although at concentrations far less than the 0.5 mg/ L

injected. The calorifier/water heater should act as a barrier to dispersal of any pathogenic material by

the hot water system (even if the cold water supply quality is not under control). Chlorine dioxide and

its breakdown products chlorite and chlorate can be deleterious to neonates and renal dialysis

patients, and should be removed from the water supply to these units.

For all practical purposes in water, ppm = mg/L.

Maintenance of the control regimen

This depends on four separate aspects, as follows:

ensuring that the dosing equipment is operating satisfactorily

ensuring that the limit for total oxidant in the system is not exceeded

ensuring that all the parts of cold and blended water systems are exposed to chlorine dioxide

ensuring that a management system is in place to maintain these procedures


It is normally the responsibility of the supplier of the dosing equipment, who will seek to achieve the



temperature is raised by: a) heat build up due to solar gain or the proximity to hot water services, or


not exceed one day’s usage.

Seasonal variation. In the summertime it is not unusual to have incoming mains supplies exceeding

20 °C. When this occurs systems should be reassessed with the likely outcome of increasing regular

flushing to these outlets in a safe manner with minimal aerosolation.





satisfy the requirements of BS 6920-1:2000. Lists of materials approved by the water industry

(WRAS) are published in the Water Fittings and Materials Directory (see Standards List), All new and

replacement water fittings should satisfy Water Supply (water fittings) Regulations 1999 and the

Scottish Water Bylaws 2004 requirements and be listed in the WRAS

(www.wras.co.uk/simple_steps_to_approval.asp) directory.


accordance with the procedures laid down in BS 6700:2006 +A1: 2009 and as per chemical

manufacturers specification


up and stagnation can occur.

When temperature problems are encountered and remedial works are not practical in order to

engineer out the problems, Chlorine Dioxide Dosing can be used.

Chlorine dioxide is an oxidising biocide that is capable of reacting with a wide range of organic

substances. In the inactivation of microorganisms, the chlorine dioxide molecule acts as a free radical

(oxidising biocide) that readily bonds with the amino acids (the basic building blocks of proteins, which

form the living cells). This results in their destruction.

Chlorine dioxide as a control measure

The use of chlorine dioxide as a control measure will depend on the design of the systems in use and

their operational history.

There are two aspects to be taken into consideration:

a). in the cold water distribution system, chlorine dioxide will be injected into the system upstream of

all parts of the distribution, storage and boosting equipment - that is, at the curtilage of the premises.

Backflow prevention is required if chlorine dioxide is injected into a pipe connected to the mains

supply.

b). in the case of hot water distribution systems with calorifiers/water heater operating conventionally

(that is, at 60°C), there will be a tendency for chlorine dioxide to be lost by "gassing off", especially if

the retention time in a vented calorifier/water heater is long. In most cases, however, some level of

total oxidant should be found in the hot water, although at concentrations far less than the 0.5 mg/ L

injected. The calorifier/water heater should act as a barrier to dispersal of any pathogenic material by

the hot water system (even if the cold water supply quality is not under control). Chlorine dioxide and

its breakdown products chlorite and chlorate can be deleterious to neonates and renal dialysis

patients, and should be removed from the water supply to these units.

For all practical purposes in water, ppm = mg/L.

Other

Page 604 of 614

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maximum available chlorine dioxide from the generation process. (Systems are not 100% efficient and

the free available chlorine dioxide may be less than the permitted limit of total oxidant of 0.5 mg/ L but

should not be significantly less at the point of injection.) When chemical treatment is introduced as

part of a programme of remedial action of a colonised system, as the system is brought under control,

it should be possible to measure increasing concentrations of available (active) chlorine dioxide. With

a newly installed dosing system, this may not be possible for several weeks. If chlorine dioxide cannot

be identified, tests for total oxidant should be performed.

It will be the responsible person or similar to take responsibility to check that the equipment is

operating and this should include routine checking of available "active" chlorine dioxide on a daily

basis.

Tests for total oxidant are most easily accomplished by DPD1 tablets. The oxidising effect of chlorine

can be removed by first adding glycine and the remaining total oxidants (including chlorine dioxide,

chlorite and chlorate) can then be measured using the DPD1 tablets, following suppliers' instructions.

DPD is an abbreviation for diethyl-p-phenylene diamine. DPD1 tablets are used for detecting oxidants

in water. ensuring that the limit for total oxidant in the system is not exceeded.

The available chlorine dioxide and total oxidant, therefore, will be the result of the disinfection process,

general state of the system and water usage levels. Performance of the dosing equipment is normally

the responsibility of the supplier/service provider. (Water quality overall is ultimately the responsibility

of the owners of the system.)

A representative number of outlets should be tested for total oxidant to ensure that the limits are not

being exceeded. These should include proximal outlets and some distal outlets. (It is not necessary to

check the hot water service.), this ensures that all parts of cold and blended water systems are

exposed to chlorine dioxide.

In addition to the above, it will be necessary to monitor the following:

the quantity of chemicals in the reservoir;

the rate of addition of chlorine dioxide to the water supply;

on a monthly basis, the concentration of chlorine dioxide should be measured at the sentinel taps and

should be at least 0.1 mg/L and no more than 0.5 mg/L

on an annual basis, the chlorine dioxide should be measured at a representative number of outlets

and should be at least 0.1 mg/L and no more than 0.5 mg/L

N.B. Prior to commissioning new equipment, a thorough disinfection of the services to be continually

dosed with chlorine dioxide is required in order to remove as much biofilm as possible. This should be

carried out in order for the new system to settle down in a reasonable time and to ensure levels are

reached throughout the system without the need for overloading in order to reach acceptable levels at

the farthest point in the system.

Maintenance of the control regimen

This depends on four separate aspects, as follows:


ensuring that the limit for total oxidant in the system is not exceeded

ensuring that all the parts of cold and blended water systems are exposed to chlorine dioxide

ensuring that a management system is in place to maintain these procedures


It is normally the responsibility of the supplier of the dosing equipment, who will seek to achieve the

maximum available chlorine dioxide from the generation process. (Systems are not 100% efficient and

the free available chlorine dioxide may be less than the permitted limit of total oxidant of 0.5 mg/ L but

should not be significantly less at the point of injection.) When chemical treatment is introduced as

part of a programme of remedial action of a colonised system, as the system is brought under control,

it should be possible to measure increasing concentrations of available (active) chlorine dioxide. With

a newly installed dosing system, this may not be possible for several weeks. If chlorine dioxide cannot

be identified, tests for total oxidant should be performed.

It will be the responsible person or similar to take responsibility to check that the equipment is

operating and this should include routine checking of available "active" chlorine dioxide on a daily

basis.

Tests for total oxidant are most easily accomplished by DPD1 tablets. The oxidising effect of chlorine

can be removed by first adding glycine and the remaining total oxidants (including chlorine dioxide,

chlorite and chlorate) can then be measured using the DPD1 tablets, following suppliers` instructions.

DPD is an abbreviation for diethyl-p-phenylene diamine. DPD1 tablets are used for detecting oxidants

in water. ensuring that the limit for total oxidant in the system is not exceeded.

The available chlorine dioxide and total oxidant, therefore, will be the result of the disinfection process,

general state of the system and water usage levels. Performance of the dosing equipment is normally

the responsibility of the supplier/client. (Water quality overall is ultimately the responsibility of the

owners of the system.)

A representative number of outlets should be tested for total oxidant to ensure that the limits are not

being exceeded. These should include proximal outlets and some distal outlets. (It is not necessary to

check the hot water service.), this ensures that all parts of cold and blended water systems are

exposed to chlorine dioxide.

In addition to the above, it will be necessary to monitor the following:

the quantity of chemicals in the reservoir;

the rate of addition of chlorine dioxide to the water supply;

on a monthly basis, the concentration of chlorine dioxide should be measured at the sentinel taps and

should be at least 0.1 mg/L and no more than 0.5 mg/L

on an annual basis, the chlorine dioxide should be measured at a representative number of outlets

and should be at least 0.1 mg/L and no more than 0.5 mg/L

Page 605 of 614

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Prior to commissioning new equipment, a thorough disinfection of the services to be continually dosed

with chlorine dioxide is required in order to remove as much biofilm as possible. This should be

carried out in order for the new system to settle down in a reasonable time and to ensure levels are

reached throughout the system without the need for overloading in order to reach acceptable levels at

the farthest point in the system.

Page 606 of 614

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CHLORINE DIOXIDE LOW DOSING DOMESTIC WATER SYSTEMS65-14 65-14 CHLORINE DIOXIDE LOW DOSING DOMESTIC WATER SYSTEMS

Sampling and maintenance of chlorine dioxide low dosing

All other requirements for operations and maintenance should be carried out as in the O & M Manual

and normally carried out by the installer/supplier of the equipment

Sampling and maintenance of chlorine dioxide low dosing. All other requirements for operations and

maintenance should be carried out as in the O & M Manual and normally carried out by the

installer/supplier of the equipment

Other


1. Sampling Take sample from first outlet from

the dosing system and test for

C102 concentration. Top up

chemical storage

Adjust dosing according to results.

Not to dose > 0.5 mg/l in drinking

water. In Cat' two fluid, dosage can

be raised to 1 mg/l, be aware of

possible metal corrosion over time.

1W 1. Sampling Take sample from first outlet from

the dosing system and test for Cl02

concentration. Top up chemical

storage

Adjust dosing according to results.

Do not dose if the test results show

levels greater than 0.5 mg/l in

drinking water. In Cat` two fluid,

dosage can be raised to 1 mg/l, be

aware of possible metal corrosion

over time.

1WOther

2. Sampling Sample sentinel outlets for C102

and log in logbook

Ensure dose level is maintained and

in drinking water does not exceed

0.5 mg/l

1M 2. Sampling Sample sentinel outlets for Cl02

and log in logbook

Ensure dose level is maintained and

in drinking water does not exceed

0.5 mg/l

1MOther

Page 607 of 614

WHIRLPOOLS-HYDROTHERAPY

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WHIRLPOOL/SPA BATHS66-01 66-01 WHIRLPOOL/SPA BATHS

Note: Frequency of maintenance will depend upon use, the quality of the water and must be agreed

with client.

A spa pool is designed for sitting or lying in up to the neck, and not for swimming. It is a self-contained

body of water that is filtered and chemically disinfected. A spa pool is not drained, cleaned or refilled

after each user, but after a number of users or a maximum period of time

Whirlpool baths are typically found in beauty parlours, health suites, hotels and dwellings. Water

within the bath is untreated and the bath is drained following each session.

Spa pools

All actions should be taken in line with manufacturers specifications and all guidance should be

followed as set out in the HPA guidance publication on Management of Spa Pools

(www.hpa.org.uk/Publications/)

Frequency of maintenance will depend upon use, the quality of the water and must be agreed with the

client. There must be a written risk assessment for the equipment, which will detail the necessary

maintenance frequencies. This is updated, usually on an annual basis and therefore musty be check

to ensure the maintenance frequencies have not altered.


cleaning the suction filter (if fitted) on a daily basis.

Other


7. Air Filter Clean Input air filter when fitted.1MAdded

8. Safety Systems Check all automatic systems are

operating correctly e.g. safety

cut-outs, automatic timers etc.

1MAdded

9. Water

Treatment

Disinfectant/pH controller - clean

electrode and check calibration

(see manufacturers instructions).

1MAdded

10. Sand Filter Thoroughly check sand filter or

diatomaceous earth filter

membranes

3MAdded

11. Air Lines Where possible clean and

disinfect airlines

3MAdded

12. Sand Filter Check sand filter efficiency12MAdded

1. Bath hygiene. Clean pipework, pump and nozzles. Fill bath with warm water to normal

level, add sterilising solution or low

foaming dishwasher powder and

operate for 10 minutes. Refill with

cold water and operate for five

minutes.

12M 1. Bath hygiene. The following action must be

carried out everytime the pool is

refilled. Clean pipework, pump and

nozzles.

Fill bath with warm water to normal

level, add cleaning/sterilizing

solution and operate for 10

minutes. Refill with cold water and

operate for five minutes.

Other

2. Suction filter (if

fitted).

Clean.12M 2. Suction filter (if

fitted).

Clean.1MLegislative

3. Nozzle jets. Clean and remove scale, refit and

regulate flow rates.

Scale may build up in hard water.

Client should be informed of the

possible need for water treatment.

12M 3. Accessible

Pipework and

Nozzle jets.

Clean and inspect for bio film.

Remove scale, refit and regulate

flow rates.

Scale may build up in hard water.

The client should be informed of the


1MLegislative

Page 609 of 614

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4. Electrical

safety.

Check operation of earth leakage

circuit breaker.

Press test button on earth leakage

circuit breaker at least once every

three months.

12M 4. Electrical

safety.

Check operation of earth leakage

circuit breaker.

Press test button on earth leakage

circuit breaker at least once every

three months.

1MLegislative

6. Timer (where

fitted).

Check operation.12M 6. Timer (where

fitted).

Check operation.1MTechnical

Page 610 of 614

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HYDROTHERAPY POOLS66-02 66-02 HYDROTHERAPY POOLS

SPA POOLS

All actions should be taken in line with manufacturers specifications and all guidance should be

followed as set out in the HPA guidance publication on Management of Spa Pools

HYDROTHERAPY POOLS

Hydrotherapy is a long established branch of physiotherapy in which patients develop strength and

suppleness during exercise sessions in a pool. Hydrotherapy pools carry similar infection hazards to

swimming pools. In addition, however, they operate with higher water and air temperatures and serve

a population both more vulnerable to infection and more likely to cause accidental contamination. A

second edition of Hygiene for hydrotherapy pools has been published. The book aims to provide

practical advice on the general management of hydrotherapy pools, patient safety, general hygiene

and pool water quality for all those (physiotherapists, engineers, domestic staff, microbiologists and

managers) involved in their installation, maintenance and management. The primary aim is to enable

the recognised difficulties associated with the use of hydrotherapy pools to be avoided , with resulting

benefit to staff and patients.

It is essential that detailed records of maintenance activities are kept in respect of any maintenance

carried out on hydrotherapy pools and a copy given to the client.

HYDROTHERAPY POOLS

Hydrotherapy is a long established branch of physiotherapy in which patients develop strength and

suppleness during exercise sessions in a pool. Hydrotherapy pools carry similar infection hazards to

swimming pools. In addition, however, they operate with higher water and air temperatures and serve

a population both more vulnerable to infection and more likely to cause accidental contamination. The

Public Health Laboratory Service have published a document called. Hygiene for hydrotherapy pools .

The book aims to provide practical advice on the general management of hydrotherapy pools, patient

safety, general hygiene and pool water quality for all those (physiotherapists, engineers, domestic

staff, microbiologists and managers) involved in their installation, maintenance and management. The

primary aim is to enable the recognised difficulties associated with the use of hydrotherapy pools to be

avoided, with resulting benefit to staff and patients.

It is essential that detailed records of maintenance activities are kept in respect of any maintenance

carried out on hydrotherapy pools and a copy given to the client.


cleaning the suction filter (if fitted) on a daily basis.

Other


1. Pool cleaning. Drain pool, inspect and thoroughly

clean.

Frequency will depend on usage

and should be agreed with client.

Report any defects which cannot be

easily remedied.

12M 1. Pool cleaning. Drain pool, inspect and thoroughly

clean.

Frequency will depend on usage

and should be agreed with the

client. Report any defects which

cannot be easily remedied.

12MOther

2. Filters. See section FILTERS. Frequency will depend on usage

and should be agreed with client.

12M 2. Suction Filters. Clean Filters1MTechnical

3. Water

treatment and

quality.

See section WATER TREATMENT.12M 3. Water

treatment and

quality.

See section Water treatment SFG

65.

12MOther

4. Circulatory

pipework,

including solar

panels (where

fitted).

Isolate from pool and drain down.

Clean out and dry.

12MAdded

5. Automatic air

vents.

Remove, drain and clean.12MAdded

6. Heating

equipment - Oil -

Solar

-Gas




sections.




6MAdded

Page 611 of 614

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a) Filtration plant. The filtration plant of

a pool is designed to remove water

from the pool, filter it, disinfect it

and return it to the pool in a sterile

condition. The main types of pool

filters are:

a) Conventional rate pressure sand

filtration

b) Medium rate pressure sand

filtration


d) Pre-coat cartridge (pressure and

vacuum)

e) Disposable cartridge or glass

fibre mat filtration

Added

7. Conventional,

medium and high

rate pressure

filtration

The terms conventional, medium

and fast rate refer to the rate of flow

of water through the filter. The

maintenance requirements for the

three types is similar.

Added

8. Inlet strainer. Check condition and clean. More frequent cleaning by the




suction pressure).

1MAdded

9. Chemical

cleaning of filter

bed material.

Check clean `running` pressure, if


medium.

Refer to manufacturer`s handbook



6MAdded

10. Rate of flow

indicator.



3MAdded

11. Pre-coat

filtration 1. Inlet

strainer.





suction pressure).

1MAdded

12. Filter

elements.



elements.


the client.

1MAdded

15. Cartridge type

filters 1. Inlet

strainer.





suction pressure).

1MAdded

16. Seals. Check condition of seals on


necessary.

1MAdded

Page 612 of 614

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17. Rate of flow

indicator.



3MAdded

Page 613 of 614

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STEAM ROOMS and HUMIDIFIERS66-03 66-03 STEAM ROOMS and HUMIDIFIERS


4. Ventilation Check operation of all ventilation

fans (supply and extract)

For more detailed information on the

maintenance requirements for

steam generation see Fans -

ventilation SFG 20-03.

6MAdded

5. Internal

Surfaces

Check internal surfaces for cracks

in the tiles or grouting. Repair as

necessary with silicone sealant

Generally, the day to day cleaning

of the internal surfaces should be

undertaken by the operational staff.

Cracks or chips in the surfaces can

be a breeding ground for bacteria.

3MAdded

Steam production

1. Generator.

Check operating thermostat timer

and earth leakage circuit breaker.



steam generation see

BOILER/HEAT GENERATORS.

12M 1. Steam

Generator

Check operation of steam

generator . Check operation of

thermostat timer and earth leakage

breaker.

Descale electrical element if

necessary.



steam generation see Humidifiers

including disinfection procedures

SFG 33-03.

Scale may build up in hard water

areas. The client should be

informed of possible need for water

treatment.

3MTechnical

2. Electric

element.

Descale electrical element if

necessary.

Scale may build up in hard water

areas. Client should be informed of


12M 2. Lighting Check operation of Lighting and

Emergency Lighting



steam generation see Lighting SFG

36-01 to 36-03 and Lighting

-emergency SFG 37-01.

1MTechnical

3. General. See BOILERS/HEAT

GENERATORS for more specific

information on the maintenance of

steam generators.

12M 3. Drainage Check that the drains in the room

are clear and allow all excess water

to drain away from the room

1MTechnical

Page 614 of 614

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